Bonding wood or other plant products using ultrasound energy

ABSTRACT

A filler material is applied to a plurality of wood elements. The plurality of wood elements is bonded into a composite wood product, where the bonding includes delivering ultrasound energy to the plurality of wood elements. The ultrasound energy has a frequency within a frequency range of 10 kHz-20 MHz.

TECHNICAL FIELD

This document generally describes devices, systems, and methods forbonding wood or other plant products using ultrasound energy.

BACKGROUND

Engineered wood products have been manufactured using lumber, veneers,wood strands, or other small wood elements, and binding them togetherwith resin to form structural products. In this manner, smaller orlower-grade logs or wood elements can be used to produce large-lumbersubstitutes. Engineered wood products have been used in structuralapplications such as girders, beams, joists, headers, studs, andcolumns, and have been used instead of, or together with, lumberproducts.

Ultrasound energy has been used for diagnostic imaging in medicalapplications. With ultrasound imaging, a probe transmits high-frequencysound pulses into a body. The sound pulses propagate as waves into thebody, passing through some bodily fluids and body tissues, while beingpartially absorbed by other body tissues, where the absorption causes apartial reflection or echo of the sound waves back towards the probe. Asensor in the probe measures the echoed sound waves, and the informationcan be used to create a diagnostic image of the area of the body beingexamined.

Ultrasound energy has also been used for diagnostic imaging andnon-destructive testing in industrial applications, such as testingwelds in metal, detecting defects within concrete or assessingconsistency of concrete, and detecting defects in wood. In oneapplication, a probe transmits high-frequency sound pulses into thematerial to be imaged or tested, and a sensor in the probe measuresechoed sound waves that return to the probe. In another application, aseparate receiver unit on a side of the material opposite the probereceives sound waves that pass through the material being imaged ortested after the probe transmits high-frequency sound pulses into thematerial.

SUMMARY

In a general aspect, a method for manufacturing a composite wood productincludes applying a filler material to a plurality of wood elements, andbonding the plurality of wood elements into a composite wood product,where the bonding includes delivering ultrasound energy to the pluralityof wood elements. The ultrasound energy has a frequency within afrequency range of 10 kHz-20 MHz.

Implementations can include one or more of the following. An ultrasoundtransducer may deliver the ultrasound energy. The filler material mayinclude an adhesive, or may not include an adhesive. The filler materialmay include a plastic. The filler material may include a metal. Theplurality of wood elements may be arranged, prior to the bonding theplurality of wood elements, in a proximity to one another. The applyingthe filler material to the plurality of wood elements and the deliveringof the ultrasound energy to the plurality of wood elements may occurconcurrently. The ultrasound energy may be delivered to the plurality ofwood elements prior to the applying the filler material to the pluralityof wood elements. The ultrasound energy may be delivered to theplurality of wood elements after the applying the filler material to theplurality of wood elements. The method may further include applying acompression force to the plurality of wood elements. The applying thecompression force to the plurality of wood elements may occur prior tothe delivering the ultrasound energy to the plurality of wood elements.The applying the compression force to the plurality of wood elements mayoccur concurrently with the delivering the ultrasound energy to theplurality of wood elements. The applying the compression force to theplurality of wood elements may occur after the delivering the ultrasoundenergy to the plurality of wood elements. The ultrasound energy may havea frequency within a frequency range of 15 kHz-1 MHz. The ultrasoundenergy may have a frequency within a frequency range of 20 kHz-100 kHz.The method may further include inspecting the composite wood product fora defect, where the inspecting includes delivering ultrasound energy tothe composite wood product. The method may further include, prior to theapplying the filler material, pretreating the plurality of woodelements, where the pretreating includes delivering ultrasound energy tothe plurality of wood elements. The pretreating including deliveringultrasound energy to the plurality of wood elements may clean theplurality of wood elements. The method may further include, after thebonding into the composite wood product, applying a treatment to thecomposite wood product and delivering ultrasound energy to the compositewood product.

The details of one or more implementations are depicted in theassociated drawings and the description thereof below. Certainimplementations may provide one or more advantages. For example,implementations of the disclosed methods, devices and systems can beused to manufacture composite wood products that are stronger (e.g., oneor more of higher tensile strength, higher compressive strength, highershear strength) than composite wood products manufactured usingtraditional techniques. As another example, implementations of thedisclosed methods, devices and systems can be used to manufacturecomposite wood products that have improved durability, as compared tocomposite wood products manufactured using traditional techniques. Asyet another example, implementations of the disclosed methods, devicesand systems can be used to manufacture composite wood products that haveimproved moisture resistance, as compared to composite wood productsmanufactured using traditional techniques. As yet another example,implementations of the disclosed methods, devices and systems can beused to manufacture composite wood products that have improvedresistance to heat, as compared to composite wood products manufacturedusing traditional techniques. As yet another example, implementations ofthe disclosed methods, devices and systems can be used to manufacturecomposite wood products that have increased hardness, as compared tocomposite wood products manufactured using traditional techniques. Asyet another example, implementations of the disclosed methods, devicesand systems can be used to improve (e.g., expedite or speed up) the rateof curing or reduce the curing time in manufacturing composite woodproducts, as compared to the rate of curing or curing time of compositewood products manufactured using traditional techniques. As yet anotherexample, implementations of the disclosed methods, devices and systemscan be used to manufacture composite wood products that have improvedresistance to insects or vermin, as compared to composite wood productsmanufactured using traditional techniques.

Other features, objects, and advantages of the technology described inthis document will be apparent from the description and the drawings,and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of an example environment for manufacturingcomposite wood products using ultrasound energy.

FIG. 2 is a conceptual diagram of example wood elements on or in anexample funnel, to be deposited onto an example conveyor, as part of anexample manufacturing process to produce composite wood products usingultrasound energy.

FIG. 3A is a view of an example application of filler material to aplurality of wood elements.

FIG. 3B is a view of another example application of filler material to aplurality of wood elements.

FIG. 3C is a view of yet another example application of filler materialto a plurality of wood elements.

FIG. 4 is a conceptual diagram of an example ultrasound transducerdelivering ultrasound energy to a plurality of example wood elements formanufacturing a composite wood product using ultrasound energy.

FIG. 5 is a conceptual diagram of the example ultrasound transducer ofFIG. 4.

FIG. 6A is a conceptual diagram of an example ultrasound transducer thatincludes an example cymbal-shaped horn that can be used formanufacturing composite wood products using ultrasound energy.

FIG. 6B is a conceptual diagram of an example ultrasound transducer thatincludes an example Langevin horn that can be used for manufacturingcomposite wood products using ultrasound energy.

FIG. 6C is a conceptual diagram of an example ultrasound transducer thatincludes an example ring-shaped horn that can be used for manufacturingcomposite wood products using ultrasound energy.

FIG. 6D is a conceptual diagram of an example ultrasound transducer thatincludes an example pyramid-shaped horn that can be used formanufacturing composite wood products using ultrasound energy.

FIG. 6E is a conceptual diagram of an example ultrasound transducer thatincludes an example sphere-shaped horn that can be used formanufacturing composite wood products using ultrasound energy.

FIG. 6F is a conceptual diagram of an example ultrasound transducer thatincludes an example dome-shaped horn that can be used for manufacturingcomposite wood products using ultrasound energy.

FIG. 6G is a conceptual diagram of an example ultrasound transducer thatincludes an example wedge-shaped horn that can be used for manufacturingcomposite wood products using ultrasound energy.

FIG. 6H is a conceptual diagram of an example ultrasound transducer thatincludes an example horn, generally shaped as a tube or a cylinder,which can be used for manufacturing composite wood products usingultrasound energy, where the horn includes an example chamber.

FIG. 7 is a flowchart of an example method that can be used tomanufacture a composite wood product.

FIG. 8 is a block diagram of an example environment for manufacturingcomposite wood products using ultrasound energy.

FIG. 9 is a conceptual diagram of an example environment formanufacturing composite wood products using ultrasound energy.

FIG. 10A is a conceptual diagram of an example press and an exampleultrasound transducer that is integral with the press, and that can beused for manufacturing composite wood products using ultrasound energy.

FIG. 10B is a conceptual diagram of another example press and exampleultrasound transducers that are integral with the press, and that can beused for manufacturing composite wood products using ultrasound energy.

FIG. 10C is a conceptual diagram of yet another example press andexample ultrasound transducers that are integral with the press, andthat can be used for manufacturing composite wood products usingultrasound energy.

FIG. 11A is a block diagram of an example environment for manufacturingcomposite wood products using ultrasound energy.

FIG. 11B is a block diagram of an example environment for manufacturingcomposite wood products using ultrasound energy.

FIG. 11C is a block diagram of an example environment for manufacturingcomposite wood products using ultrasound energy.

FIG. 12A is a conceptual diagram of an example environment formanufacturing composite wood products using ultrasound energy, where theexample environment includes an example ultrasound transducer thatincludes an example roller element.

FIG. 12B is a conceptual diagram of another example ultrasoundtransducer that includes another example roller element.

FIG. 12C is a conceptual diagram of an example environment formanufacturing composite wood products using ultrasound energy.

FIG. 13A is a side view of an example roller element.

FIG. 13B is a side view of another example roller element.

FIG. 13C is a side view of yet another example roller element.

FIG. 14A is a front view and FIG. 14B is a top view of an exampleportion of an example roller element that includes a plurality ofexample protrusions.

FIG. 14C is a front view and FIG. 14D is a top view of an exampleportion of an example roller element that includes a plurality ofexample recessed features.

FIG. 14E is a front view of an example portion of an example rollerelement that includes one or more example protrusions and one or moreexample recessed features.

FIG. 15A is a conceptual diagram of an example control module and anexample ultrasound transducer delivering ultrasound energy to aplurality of example wood elements for manufacturing a composite woodproduct using ultrasound energy.

FIG. 15B is a block diagram of the example control module of FIG. 15A.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

Described herein are devices, systems and methods that can be used tobond wood or other plant products using ultrasound energy. With someimplementations of the devices, systems and methods described herein, acomposite wood product can be manufactured by applying a filler materialto a plurality of wood elements and bonding the plurality of woodelements into a composite wood product, where the bonding comprisesdelivering low frequency ultrasound energy to the plurality of woodelements. For example, the low frequency ultrasound energy may have afrequency in the range of 10 kHz to 20 MHz. In some implementations, thelow frequency ultrasound energy may have a frequency in the range of 15kHz to 1 MHz. In some implementations, the low frequency ultrasoundenergy may have a frequency in the range of 20 kHz to 100 kHz.

An ultrasound transducer can be used to provide the ultrasound energyused in bonding the plurality of wood elements into the composite woodproduct. In various implementations, the ultrasound transducer producesultrasound waves, which may convey the ultrasound energy to theplurality of wood elements and the filler material. In some examples,the ultrasound waves may be delivered as continuous waves, and in someexamples the ultrasound waves may be delivered as pulsed waves. In someexamples, the transducer can deliver periodic ultrasound waves, and thewaves may include one or more of a variety of waveforms. For example, invarious implementations, the waveforms may include one or more ofsinusoidal waveforms, rectangular waveforms, square waveforms,trapezoidal waveforms, triangular waveforms, sawtooth waveforms, orother appropriate waveform shapes. The transducer may produce ultrasoundwaves that can include one or more of ultrasound longitudinal waves,ultrasound radial waves, and ultrasound shear waves, for example, wherethe ultrasound waves may deliver the ultrasound energy to the pluralityof wood elements, to the filler material, or to both the plurality ofwood elements and to the filler material.

The ultrasound energy may provide a mechanical stimulation to theplurality of wood elements. For example, as the ultrasound waves travelthrough a wood element or are absorbed by the wood element, theultrasound waves may cause molecules within the wood element to vibrate.The vibration at the molecular level within the wood element may createfriction between the vibrating molecules, which can generate heat withinthe wood element. Additionally, in some examples, as the ultrasoundwaves travel through or are absorbed by the wood element, the ultrasoundwaves may cause small or micro pressure differentials to be createdwithin the wood element. Such pressure differentials can result incavitation within the wood element, where micro-level gas or vaporbubbles may be created within the wood element as gas or vapor fromhigher-pressure areas within the wood element are forced or pushed, dueto the pressure differentials, toward lower-pressure areas within thewood element. In one or more of these manners, the ultrasound energy mayprovide a mechanical stimulation in the bonding of wood or other plantproducts, for example. This mechanical stimulation may be provided, forexample, even though the ultrasound transducer may not be in physicalcontact with the wood elements or with the filler material. In someexamples, the ultrasound transducer, or a portion of the transducer, maybe in physical contact with one or more of the wood elements, with thefiller material, or with both the filler material and one or more of thewood elements, and the aforementioned mechanical stimulation may beprovided.

The ultrasound energy may further provide a mechanical stimulation tothe plurality of wood elements, which may be arranged in a proximity toone another, at a macro level. The mechanical stimulation provided bythe ultrasound waves may cause one or more of the wood elements to moveor vibrate, for example, and such movement or vibration may createfriction between the wood elements. For example, the mechanicalstimulation provided by the ultrasound waves may cause one or more ofthe wood elements to move or vibrate, and one or more surfaces of afirst wood element may encounter resistance when moving, rubbing orvibrating in contact with one or more surfaces of one or more other woodelements (e.g., a second wood element, a second wood element and a thirdwood element, or one or more other wood elements). In one or more ofthese manners, the ultrasound energy may provide a mechanicalstimulation in the bonding of wood or other plant products, for example.This mechanical stimulation may be provided, for example, even thoughthe ultrasound transducer may not be in physical contact with the woodelements or with the filler material. In some examples, the ultrasoundtransducer, or a portion of the transducer, may be in physical contactwith one or more of the wood elements, with the filler material, or withboth the filler material and one or more of the wood elements, and theaforementioned mechanical stimulation may be provided.

Similarly, in various implementations the ultrasound waves may provide amechanical stimulation to the filler material. For example, as theultrasound waves travel through the filler material or are absorbed bythe filler material, the ultrasound waves may cause molecules within thefiller material to vibrate. The vibration at the molecular level withinthe filler material may create friction between the vibrating molecules,which can generate heat within the filler material. Additionally, insome examples, as the ultrasound waves travel through or are absorbed bythe filler material, the ultrasound waves may cause small or micropressure differentials to be created within the filler material. Suchpressure differentials can result in cavitation within the fillermaterial, where micro-level gas or vapor bubbles may be created withinthe filler material as gas or vapor from higher-pressure areas withinthe filler material are forced or pushed, due to the pressuredifferentials, to lower-pressure areas within the filler material. Inone or more of these manners, the ultrasound energy may provide amechanical stimulation in the bonding of wood or other plant products,for example. This mechanical stimulation may be provided, for example,even though the ultrasound transducer may not be in physical contactwith the wood elements or with the filler material. In some examples,the ultrasound transducer, or a portion of the transducer, may be inphysical contact with one or more of the wood elements, with the fillermaterial, or with both the filler material and one or more of the woodelements, and the aforementioned mechanical stimulation may be provided.

The ultrasound energy may further provide a mechanical stimulation tothe filler material at a macro level. For example, the mechanicalstimulation provided by the ultrasound waves may agitate the fillermaterial, and may cause the filler material to move, vibrate, diffuse,spread, flow, or penetrate, to list just a few examples. In one or moreof these manners, the ultrasound energy may provide a mechanicalstimulation in the bonding of wood or other plant products, for example.This mechanical stimulation may be provided, for example, even thoughthe ultrasound transducer may not be in physical contact with the woodelements or with the filler material. In some examples, the ultrasoundtransducer, or a portion of the transducer, may be in physical contactwith one or more of the wood elements, with the filler material, or withboth the filler material and one or more of the wood elements, and theaforementioned mechanical stimulation may be provided.

In some implementations, the ultrasound energy may stimulate diffusionof the filler material, and may cause the filler material to penetrateinto the wood elements, or deeper into the wood elements, for example.In some implementations, the ultrasound energy may stimulate diffusionof the filler material, and may cause the filler material to morebroadly spread across, cover, or contact the wood elements, for example.In one or more of these manners, the ultrasound energy may provide adiffusional stimulation in the bonding of wood or other plant products.This diffusional stimulation may be provided, for example, even thoughthe ultrasound transducer may not be in physical contact with the woodelements or with the filler material. In some examples, the ultrasoundtransducer, or a portion of the transducer, may be in physical contactwith one or more of the wood elements, with the filler material, or withboth the filler material and one or more of the wood elements, and theaforementioned diffusional stimulation may be provided.

The ultrasound energy may also provide a thermal stimulation to theplurality of wood elements, to the filler material, or to the pluralityof wood elements and to the filler material, according to someimplementations. This thermal stimulation may be in addition to any heatgenerated due to the mechanical stimulation or stimulations describedabove, for example. In some implementations, a temperature of the woodelements may increase as the wood elements absorb the ultrasound energy,or a portion of the ultrasound energy, that the transducer delivers tothe wood elements. Similarly, a temperature of the filler material mayincrease as the filler material absorbs the ultrasound energy, or aportion of the ultrasound energy, that the transducer delivers to thefiller material. The increase in temperature of the filler material, ofthe wood elements, or of both the filler material and the wood elementsmay stimulate better diffusion of the filler material in some examples,and may stimulate deeper penetration of the filler material into thewood elements, as by stimulating better flow of the filler material(e.g., in implementations where the filler material is a liquid orcapable of flowing). In one or more of these manners, the ultrasoundenergy may provide a thermal stimulation in the bonding of wood or otherplant products. This thermal stimulation may be provided, for example,even though the ultrasound transducer may not be in physical contactwith the wood elements or with the filler material. In some examples,the ultrasound transducer, or a portion of the transducer, may be inphysical contact with one or more of the wood elements, with the fillermaterial, or with both the filler material and one or more of the woodelements, and the aforementioned thermal stimulation may be provided.

In some examples, friction generated between the wood elements orbetween the filler material and the wood elements due to the applicationof the ultrasound energy can cause the filler material to be pushed ordriven into crevices, pores, gaps, spaces, voids, or cavities in one ormore of the wood elements. In some implementations, the friction maystimulate atomization of the filler material (e.g., cause the fillermaterial to be separated into smaller or finer particles), which can insome examples stimulate the filler material to be pushed or driven intocrevices, pores, gaps, spaces, voids or cavities in one or more of thewood elements. In some examples, the friction may further generate heat,which may also stimulate a deeper penetration by the filler materialinto the wood elements, for example by heating the filler material andstimulating better flow of the filler material (e.g., in implementationswhere the filler material is a liquid or capable of flowing). In one ormore of these manners, the ultrasound energy may generate frictionbetween the wood elements or between the filler material and the woodelements, which may provide a stimulation in the bonding of wood orother plant products. This stimulation may be provided, for example,even though the ultrasound transducer may not be in physical contactwith the wood elements or with the filler material. In some examples,the ultrasound transducer, or a portion of the transducer, may be inphysical contact with one or more of the wood elements, with the fillermaterial, or with both the filler material and one or more of the woodelements, and the aforementioned stimulation may be provided.

The filler material can, in various implementations, take a number ofdifferent forms. In some implementations, the filler material mayinclude an adhesive, while in other implementations the filler materialmay not include an adhesive. In some implementations, the fillermaterial may include a plastic, while in other implementations thefiller material may not include a plastic. In some implementations, thefiller material may include a metal, while in other implementations thefiller material may not include a metal. Combinations of the foregoingare also possible (e.g., filler material includes an adhesive and aplastic; filler material includes an adhesive and a metal; or fillermaterial includes an adhesive, plastic, and metal).

In some implementations, the filler material is a liquid. In someimplementations, the filler material is a solid. For example, in someimplementations the filler material may include a powder. In someimplementations, the filler material is a gas. Combinations of theforegoing examples of states of the filler material or filler materialscan also be used, according to some implementations. For example, insome implementations, the filler material may be a combination or amixture of a liquid and a solid. In some implementations, the fillermaterial may be a combination or a mixture of a liquid and a gas. Insome implementations, the filler material may be a combination or amixture of a solid and a gas. In some implementations, the fillermaterial may be a combination or a mixture of a liquid, a solid, and agas.

In some implementations, the filler material can be applied to theplurality of wood elements prior to delivering the ultrasound energy tothe plurality of wood elements. In some implementations, the fillermaterial can be applied to the plurality of wood elements concurrentlywith the delivering the ultrasound energy to the plurality of woodelements. In some implementations, the filler material can be applied tothe plurality of wood elements after delivering the ultrasound energy tothe plurality of wood elements.

In some implementations, ultrasound energy may be delivered to theplurality of wood elements both prior to the application of the fillermaterial to the plurality of wood elements and concurrently with theapplication of the filler material to the plurality of wood elements. Insome implementations, ultrasound energy may be delivered to theplurality of wood elements both concurrently with the application of thefiller material to the plurality of wood elements and after theapplication of the filler material to the plurality of wood elements. Insome implementations, ultrasound energy may be delivered to theplurality of wood elements both prior to the application of the fillermaterial to the plurality of wood elements and after the application ofthe filler material to the plurality of wood elements. In someimplementations, ultrasound energy may be delivered to the plurality ofwood elements each of prior to the application of the filler material tothe plurality of wood elements, concurrently with the application of thefiller material to the plurality of wood elements, and after theapplication of the filler material to the plurality of wood elements.

In some implementations, a compression force may be applied to theplurality of wood elements, in addition to the delivery of theultrasound energy to the plurality of wood elements. Many options arepossible regarding the compression force, and many options are possibleregarding when the compression force may be applied relative to thedelivering of the ultrasound energy. In some examples, a press can beused to apply a physical compression force to the plurality of woodelements. In some implementations, the compression force can be appliedto the plurality of wood elements concurrently with the delivering ofthe ultrasound energy to the plurality of wood elements. In someimplementations, the compression force can be applied to the pluralityof wood elements prior to the delivery of the ultrasound energy to theplurality of wood elements. In some implementations, the compressionforce can be applied to the plurality of wood elements after thedelivery of the ultrasound energy to the plurality of wood elements. Insome implementations, the compression force can beneficially aid indeveloping stronger bonds between the wood elements, for example.

Combinations of the foregoing examples of delivering ultrasound energyrelative to application of a compression force to the plurality of woodproducts can also be used, according to some implementations. Forexample, in some implementations ultrasound energy may be delivered tothe plurality of wood elements both prior to the application of thecompression force to the plurality of wood elements and concurrentlywith the application of the compression force to the plurality of woodelements. In some implementations, ultrasound energy may be delivered tothe plurality of wood elements both concurrently with the application ofthe compression force to the plurality of wood elements and after theapplication of the compression force to the plurality of wood elements.In some implementations, ultrasound energy may be delivered to theplurality of wood elements both prior to the application of thecompression force to the plurality of wood elements and after theapplication of the compression force to the plurality of wood elements.In some implementations, ultrasound energy may be delivered to theplurality of wood elements each of prior to the application of thecompression force to the plurality of wood elements, concurrently withthe application of the compression force to the plurality of woodelements, and after the application of the compression force to theplurality of wood elements.

Some implementations of the devices, systems and methods describedherein can be used to manufacture composite wood products that arestronger (e.g., one or more of higher tensile strength, highercompressive strength, higher shear strength) than composite woodproducts manufactured using traditional techniques, where ultrasoundenergy is not used. Some implementations of the devices, systems andmethods described herein can be used to manufacture composite woodproducts that have improved durability, as compared to composite woodproducts manufactured using traditional techniques, where ultrasoundenergy is not used. Some implementations of the devices, systems andmethods described herein can be used to manufacture composite woodproducts that have improved moisture resistance, as compared tocomposite wood products manufactured using traditional techniques, whereultrasound energy is not used. Improved moisture resistance can help toreduce or minimize degradation or decay of the composite wood products,for example. Some implementations of the devices, systems and methodsdescribed herein can be used to manufacture composite wood products thathave improved resistance to heat, as compared to composite wood productsmanufactured using traditional techniques, where ultrasound energy isnot used. Some implementations of the devices, systems and methodsdescribed herein can be used to manufacture composite wood products thathave increased hardness, as compared to composite wood productsmanufactured using traditional techniques, where ultrasound energy isnot used. Some implementations of the devices, systems and methodsdescribed herein can be used to improve (e.g., expedite or speed up) therate of curing or reduce the curing time in manufacturing composite woodproducts, as compared to the rate of curing or curing time of compositewood products manufactured using traditional techniques, whereultrasound energy is not used. Some implementations of the devices,systems and methods described herein can be used to manufacturecomposite wood products that have improved resistance to insects orvermin, as compared to composite wood products manufactured usingtraditional techniques, where ultrasound energy is not used. Engineeredwood products may be an environmentally friendly and desirablealternative to steel, for example because engineered wood products canbe manufactured using renewable energy sources like fast growing trees,such as, without limitation, hybrid poplar, yellow poplar, aspen,Douglas fir, western hemlock, southern pine, or other appropriatehardwood or softwood species.

FIG. 1 is a block diagram of an example environment 100 formanufacturing composite wood products using ultrasound energy. Invarious implementations, examples of the composite wood products caninclude, without limitation, girders, beams, joists, I-joists, rafters,headers, studs, trusses, columns, rim boards, plywood, particle board,fibreboard, oriented strand board, flakeboard, waferboard, chipboard,laminated timber, laminated veneer lumber, cross-laminated timber,parallel strand lumber, laminated strand lumber, and finger joints.

The environment 100 includes a wood element preparation area 102, afiller material application area 104, and an ultrasound energy deliveryarea 106. The wood element preparation area 102 can be used to prepare aplurality of wood elements for applying filler material to the pluralitywood elements and delivering ultrasound energy to the plurality of woodelements to bond the plurality of wood elements into a composite woodproduct. In some examples, the wood element preparation area 102 can beused to produce the wood elements, for example by cutting and processingtimber or other wood- or plant-based components to produce the desiredwood elements. In some examples, the wood elements can include primaryproducts of such processing, and in some examples the wood elements caninclude secondary or waste products of such processing. Examples of suchprimary or secondary wood elements can include, without limitation, woodsheets, wood veneers, wood strips, wood strands, wood chips, woodflakes, wood scraps, sawdust, other appropriate lumber or timberparticles, elements, components or products, or other appropriateplant-based particles, elements, components or products.

In some implementations, each of wood element preparation area 102,filler material application area 104 and ultrasound energy delivery area106 may be located within one facility. In some implementations, one ormore of wood element preparation area 102, filler material applicationarea 104, and ultrasound energy delivery area 106 may be located withina facility different from one or more of the other areas 102, 104, 106.To list just one example, in some implementations wood elementpreparation area 102 may be located in a first facility, and fillermaterial application area 104 and ultrasound energy delivery area 106may be located in a second facility.

Within the wood element preparation area 102, a variety of processes cantake place, in some cases depending on the type of wood elementsdesired. In some examples, timber can be debarked in the wood elementpreparation area 102. For example, debarking machinery may strip barkfrom the timber at this stage. In some examples, prior to debarking, thetimber can be cut to appropriate lengths in the wood preparation area102. In some examples, after debarking, the debarked timber can be cutto appropriate lengths in the wood preparation area 102. In someexamples, the debarked timber can be soaked in a liquid bath (e.g., awater bath) or steamed with vapor (e.g., water vapor), for example tosoften the wood fiber of the timber in the wood element preparation area102. In some examples, the debarked timber is not subjected to a liquidbath or steam treatment.

In some examples, the debarked timber can be cut into sheets, veneers,strips, strands, chips, flakes, or other types of wood elements using,for example, a wood lathe, and in some examples one or more cuttingapparatuses, such as various types of saws. In some examples, the one ormore cutting apparatuses may cut to particular lengths, may cut toparticular desired angles, may cut one or more grooves, or may makeother specialized cuts, depending upon the particular implementation. Insome examples, such cutting may produce wood scraps or sawdust that canalso be used in some implementations. In some examples, one or moredryers can be used for one or more drying steps to reduce the moisturecontent of the wood sheets, veneers, strips, strands, chips, flakes,scraps, sawdust, or other types of wood elements, and in variousimplementations the one or more drying steps can occur before or afterthe cutting steps in the wood element preparation area 102.

Referring again to FIG. 1, before the wood elements are provided to thefiller material application area 104, in some examples, the woodelements may be arranged in a proximity to one another within the woodelement preparation area 102. There are many different ways that thiscan be done, some of which can involve the wood elements being arrangedin a proximity to one another using one or more automated processes(e.g., using one or more machines to arrange), using one or more manualprocesses (e.g., using one or more workers manually arranging), or usinga combination of one or more automated processes and one or more manualprocesses.

FIG. 2 is a conceptual diagram 120 of example wood elements 122 on or inan example funnel 124, to be deposited onto an example conveyor 126, aspart of an example manufacturing process to produce composite woodproducts using ultrasound energy. The funnel 124 and conveyor 126 (or aportion of the conveyor 126) may be included in some implementations ofthe wood element preparation area 102, for example. In this illustrativeexample, the example wood elements 122 include a wood sheet 128, a woodveneer 130, a wood strip 132, a wood strand 134, wood chips 136, woodflakes 138, wood scraps 140, and sawdust 142. In some examples, otherappropriate plant-based particles or plant-based elements, components orproducts could similarly be included, but are not shown in FIG. 2 forbrevity. While multiple types of wood elements 128, 130, 132, 134, 136,138, 140, 142 are shown together on the funnel 124 of FIG. 2 forillustrative purposes, in some examples only a single type of woodelement (e.g., only wood sheets 128, or only wood strips 132, or any ofthe other depicted wood elements 130, 134, 136, 138, 140, 142,singularly) may be processed at a given time, and in such examples thefunnel 124 may generally include only the particular type of woodelement being processed at the time. In some examples, a subset of thedepicted wood element types, such as any two of the wood element types,or any three (or more) of the wood element types, may be processed at agiven time, and in such examples the funnel 124 may generally includethose particular types of wood elements.

The conveyor 126 may take various forms. In some examples, the conveyor126 can include one or more belts. In some examples, the conveyor 126can include one or more rollers (e.g., a series of rollers). In someexamples, the conveyor 126 can include one or more chains. Combinationsof the foregoing conveyor examples are also possible. In general,conveyor 126 may transport the wood elements deposited from the funnel124 onto the conveyor 126 in a direction 144 towards the filler materialapplication area 104, according to some implementations. FIG. 2 showsthe funnel 124 depositing the wood elements onto the conveyor 126, butin other examples the funnel 124 may not be used, and one or moremachines may place the wood elements onto the conveyor 126. In yet otherexamples, wood elements may manually be placed onto the conveyor byworkers, for example.

In some examples, conveyor 126 may include an arrangement feature or astacking feature, to arrange or stack (or both) the wood elements into aparticular configuration. In some examples, one or more machines orapparatuses (not shown in FIG. 2 for brevity) different from theconveyor 126 may arrange or stack (or both) the wood elements into aparticular configuration. In some examples, one or more workers maymanually arrange or stack (or both) the wood elements into a particularconfiguration. In some examples, a conveyor may not be used to transportwood elements to the filler material application area 104, to theultrasound energy delivery area 106, or to transport wood elementswithin area 104 or area 106, for example.

The examples that follow will assume, for simplicity, that a single typeof wood element is used in the filler material application area 104 andthe ultrasound energy delivery area 106. In other examples, two or more(e.g., two, three, four, five, or more) types of wood elements can beused in the filler material application area 104 and the ultrasoundenergy delivery area 106 to manufacture composite wood products.

FIG. 3A is a view 150 of an example application of filler material to aplurality of wood elements. A plurality of wood elements 152 arearranged on a conveyor 154, and are travelling in a direction 156 basedon movement of the conveyor 154. In this example, the depicted woodelements 152 are wood chips, but in other examples the wood elements mayalternatively be wood sheets, wood veneers, wood strips, wood strands,wood flakes, wood scraps, sawdust, other appropriate lumber or timberparticles, elements, components or products, or other appropriateplant-based particles, elements, components or products, or combinationsof the foregoing. In some examples, conveyor 154 may correspond toconveyor 126 of FIG. 2, and in other examples conveyor 154 may be adifferent conveyor than conveyor 126 of FIG. 2.

Example applicators 158 are positioned, in this example, above theconveyor 154, and may dispense filler material 160 onto the woodelements 152 as the wood elements 152 pass under the applicators 158. Inthe example of FIG. 3A, the applicators 158 are spray nozzles, which mayspray the filler material 160 onto the wood elements 152. In thisexample, the applicators 158 may not come into physical contact with thewood elements 152. In some examples, the filler material 160 includes anadhesive. In some implementations, the filler material 160 does notinclude an adhesive. In some implementations, the filler material 160includes a plastic, and in some implementations the filler material 160does not include a plastic. In some implementations, the filler material160 includes a metal, and in other implementations the filler material160 does not include a metal. As described above herein, combinations ofsuch materials are also possible for the filler material 160.

As can be seen in FIG. 3A, in general, those wood elements 162 that havenot yet passed under the applicators 158 have not yet had fillermaterial 160 applied to the wood elements 162, while, in general, thosewood elements 164 that have passed under the applicators 158 have hadfiller material 160 applied to the wood elements 164. Referring again toFIG. 1, the application of filler material shown in FIG. 3A may occur infiller material application area 104, for example. The view 150 depictsfour spray nozzle applicators, but in other examples one, two, three, orfive or more applicators 158 may alternatively be used to apply fillermaterial 160 to the plurality of wood elements 152. The applicators 158may be supplied filler material 160 by a filler material supply line166, for example. In examples where the filler material 160 includes anadhesive, the applicators 158 may be individually or collectivelyconsidered an adhesive applicator, for example.

FIG. 3B is a view 180 of another example application of filler materialto a plurality of wood elements. A plurality of wood elements 182 arearranged on a conveyor 184, and are travelling in a direction 186 basedon movement of the conveyor 184. In this example, the depicted woodelements 182 are wood strips, but in other examples the wood elementsmay alternatively be wood sheets, wood veneers, wood chips, woodstrands, wood flakes, wood scraps, sawdust, other appropriate lumber ortimber particles, elements, components or products, or other appropriateplant-based particles, elements, components or products, or combinationsof the foregoing. In some examples, conveyor 184 may correspond toconveyor 126 of FIG. 2, and in other examples conveyor 184 may be adifferent conveyor than conveyor 126 of FIG. 2.

An example applicator 188 is positioned, in this example, above theconveyor 184, and may dispense filler material 190 from the applicator188 onto the wood elements 182 as the wood elements 182 pass under theapplicator 188. In the example of FIG. 3B, the applicator 188 is aroller element, which may rotate about an axis and roll the fillermaterial onto the wood elements 182. In this example, the applicator 188may come into physical contact with the wood elements 182. In someexamples, the filler material 190 includes an adhesive. In someimplementations, the filler material 190 does not include an adhesive.In some implementations, the filler material 190 includes a plastic, andin some implementations the filler material 190 does not include aplastic. In some implementations, the filler material 190 includes ametal, and in other implementations the filler material 190 does notinclude a metal. As described above herein, combinations of suchmaterials are also possible for the filler material 190. As can be seenin FIG. 3B, in general, those wood elements 192 that have not yet passedunder the applicator 188 have not yet had filler material 190 applied tothe wood elements 192, while, in general, those wood elements 194 thathave passed under the applicator 188 have had filler material 190applied to the wood elements 194. Referring again to FIG. 1, theapplication of filler material shown in FIG. 3B may occur in fillermaterial application area 104, for example. The view 180 depicts asingle applicator 188, but in other examples two or more applicators(e.g., two or more smaller rollers) may alternatively be used to applyfiller material 190 to the plurality of wood elements 182. Theapplicator 188 may be supplied filler material 190 by a filler materialsupply line 196, for example. In examples where the filler material 190includes an adhesive, the applicator 188 may be considered an adhesiveapplicator, for example.

FIG. 3C is a view 200 of yet another example application of fillermaterial to a plurality of wood elements. A plurality of wood elements202 are arranged on a conveyor 204, and are travelling in a direction206 based on movement of the conveyor 204. In this example, the depictedwood elements 202 are wood veneers, but in other examples the woodelements may alternatively be wood sheets, wood strips, wood strands,wood chips, wood flakes, wood scraps, sawdust, other appropriate lumberor timber particles, elements, components or products, or otherappropriate plant-based particles, elements, components or products, orcombinations of the foregoing. In some examples, conveyor 204 maycorrespond to conveyor 126 of FIG. 2, and in other examples conveyor 204may be a different conveyor than conveyor 126 of FIG. 2.

An example applicator 208 is positioned, in this example, above theconveyor 204, and may dispense filler material 210 from the applicator208 onto the wood elements 202 as the wood elements 202 pass under theapplicator 208. In the example of FIG. 3C, the applicator 208 is one ormore brush elements, which may brush the filler material 210 onto thewood elements 202. In this example, the applicator 208 may come intophysical contact with the wood elements 202. In some examples, thefiller material 210 includes an adhesive. In some implementations, thefiller material 210 does not include an adhesive. In someimplementations, the filler material 210 includes a plastic, and in someimplementations the filler material 210 does not include a plastic. Insome implementations, the filler material 210 includes a metal, and inother implementations the filler material 210 does not include a metal.As described above herein, combinations of such materials are alsopossible for the filler material 210. As can be seen in FIG. 3C, ingeneral, those wood elements 212 that have not yet passed under theapplicator 208 have not yet had filler material 210 applied to the woodelements 212, while, in general, those wood elements 214 that havepassed under the applicator 208 have had filler material 210 applied tothe wood elements 214. Referring again to FIG. 1, the application offiller material shown in FIG. 3C may occur in filler materialapplication area 104, for example. The view 200 depicts a singleapplicator 208, but in other examples two or more applicators (e.g., twoor more smaller brushes) may alternatively be used to apply fillermaterial 210 to the plurality of wood elements 202. The applicator 208may be supplied filler material 210 by a filler material supply line216, for example. In examples where the filler material 210 includes anadhesive, the applicator 208 may be considered an adhesive applicator,for example.

Various examples of adhesives may be used as filler material 160, 190,210, according to various implementations. Examples of adhesives thatcan be used as filler material can include, without limitation,urea-formaldehyde resins, phenol formaldehyde resins,melamine-formaldehyde resins, polyurethane resins, and polymericmethylene diphenyl diisocyanate resins. In some examples, an urethaneadhesive or an acrylic urethane adhesive can be used. In some examples,a water-based adhesive can be used.

Following application of the filler material 160, 190, 210 in theexamples of FIGS. 3A, 3B, and 3C, in some examples the plurality of woodelements 164, 194, 214 may be arranged in a proximity to one another. Insome examples, wood elements may be arranged or stacked in a verticaldimension in a proximity to one another. For example, two or more of thewood strips 194 may be stacked vertically. As another example, two ormore of the wood veneers 214 may be stacked vertically. In someexamples, wood elements may be arranged or stacked in a horizontal orlateral dimension in a proximity to one another. Additional arrangementsare possible, such as arrangements where some of the wood elements arearranged or stacked in a vertical dimension in a proximity to oneanother and some of the wood elements are arranged or stacked in ahorizontal or lateral dimension in a proximity to one another.

In some examples, the arrangement of wood elements in proximity to oneanother may generally be structured or systematic (e.g., stacking two,three, four, five, or more wood elements in a vertical dimension, orvertically). In some examples the arrangement of wood elements inproximity to one another may generally be less structured, such as byrandomly or variably arranging a plurality or wood elements (e.g., woodchips, wood flakes, wood scraps, sawdust, or the like) in proximity toone another. For example, the wood chips 164 may generally be randomlyor variably arranged in a proximity to one another.

Arrangement of the plurality of wood elements in a proximity to oneanother may be performed using one or more automated processes (e.g., byone or more machines programmed to arrange the wood elements), using oneor more manual processes (e.g., by one or more workers manuallyperforming the wood element arrangement), or by a combination of one ormore automated processes and one or more manual processes. In someexamples, the plurality of wood elements may be arranged in a proximityto one another by being laid, or laid-up, in a “mat.”

FIG. 4 is a conceptual diagram 230 of an example ultrasound transducer232 delivering ultrasound energy to a plurality of example wood elements234 for manufacturing a composite wood product using ultrasound energy.The delivery of ultrasound energy to the plurality of example woodelements 234 shown in FIG. 4 may occur in ultrasound energy deliveryarea 106 of FIG. 1, for example. Referring again to FIG. 4, the exampleultrasound transducer 232 has a generic shape, and may represent any ofthe ultrasound transducer shapes or topologies discussed herein. Ingeneral, ultrasound transducer 232 may generate ultrasound energy, whichcan be used to bond the plurality of wood elements 234 into a compositewood product. For example, the ultrasound transducer 232 may produceultrasound waves 236, which may convey the ultrasound energy to theplurality of wood elements 234. As used herein, the term “ultrasoundtransducer” will be understood to denote a device that may generateultrasound energy, and may dispense the ultrasound energy from theultrasound transducer in the form of ultrasound or ultrasonic waves. Asused herein, the term “ultrasound transducer” does not necessarilydenote that the device includes a receiver capable of receivingultrasound waves (e.g., ultrasound waves reflected back to the device),and does not necessarily denote that the device is able to measureultrasound waves. In some implementations of the devices, systems andmethods discussed herein, ultrasound transducers can include a receiverthat may receive, and in some implementations measure, ultrasound waves,but in the particular examples discussed herein, such receiver orreceiver features are generally not included with the ultrasoundtransducers described with respect to the depicted examples herein.

In this example of FIG. 4, the plurality of wood elements 234 includesfour wood elements 238 a, 238 b, 238 c, and 238 d arranged in aproximity to one another. In this example, the wood elements aregenerally stacked on top of one another, with a first wood element 238 agenerally disposed on a surface 240, a second wood element 238 bgenerally arranged on top of the first wood element 238 a, a third woodelement 238 c generally arranged on top of the second wood element 238b, and a fourth wood element 238 d generally arranged on top of thethird wood element 238 c.

In some examples, one or more of the wood elements 238 a, 238 b, 238 c,238 d may correspond to one or more of wood elements 194 or 192 of FIG.3B. For example, one or more of the elements may include an appliedfiller material on a surface or portion of a surface, or on multiplesurfaces. For example, filler material may be disposed on a top surface242 of first wood element 238 a; filler material may be disposed on atop surface 244 of second wood element 238 b; and filler material may bedisposed on a top surface 246 of third wood element 238 c.Alternatively, for example, filler material may be disposed on bottomsurfaces of wood elements 238 b, 238 c and 238 d. In some examples, oneor more of the wood elements 238 a, 238 b, 238 c, 238 d may correspondto wood elements 194 of FIG. 3B (e.g., elements 238 a, 238 b, 238 c,each of which may have filler material disposed on their top surfaces242, 244, 246, respectively), and one or more of the wood elements 238a, 238 b, 238 c, 238 d may not correspond to the wood elements 194 ofFIG. 3B (e.g., element 238 d, which may not have filler materialdisposed on a surface of the element 238 d prior to arrangement of theelements 238 a, 238 b, 238 c, 238 d in a proximity to one another). Insome examples, filler material may not be disposed on any of thesurfaces of the wood elements 238 a, 238 b, 238 c, 238 d. This examplewill assume that filler material 248 is disposed on surfaces 242, 244,and 246.

The plurality of wood elements 238 a, 238 b, 238 c, 238 d in thisexample may correspond to a plurality of wood strands. In otherexamples, the plurality of wood elements 238 a, 238 b, 238 c, 238 d maycorrespond to a plurality of wood sheets, a plurality of wood veneers, aplurality of wood strips, a plurality of wood chips, a plurality of woodflakes, a plurality of wood scraps, sawdust, an any combination of theforegoing, or other appropriate lumber or timber particles, elements,components or products, or other appropriate plant-based particles,elements, components or products.

In some examples, the ultrasound energy, conveyed by the ultrasoundwaves 236, has a frequency within a frequency range of 10 kHz-20 MHz. Insome examples, the ultrasound energy, conveyed by the ultrasound waves236, has a frequency within a frequency range of 15 kHz-1 MHz. In someexamples, the ultrasound energy, conveyed by the ultrasound waves 236,has a frequency within a frequency range of 20 kHz-100 kHz. In general,the ultrasound transducer 232 may deliver low-frequency ultrasoundenergy to the plurality of wood elements 234.

In some examples, the ultrasound waves 236 may be delivered ascontinuous waves, and in some examples the ultrasound waves 236 may bedelivered as pulsed waves. In some examples, the transducer 232 candeliver periodic ultrasound waves, and the waves may include one or moreof a variety of waveforms. For example, in various implementations, thewaveforms may include one or more of sinusoidal waveforms, rectangularwaveforms, square waveforms, trapezoidal waveforms, triangularwaveforms, sawtooth waveforms, or other appropriate waveform shapes, orappropriate combinations of the foregoing. The transducer 232 mayproduce ultrasound waves 236 that can include one or more of ultrasoundlongitudinal waves, ultrasound radial waves, and ultrasound shear waves,for example, where the ultrasound waves 236 may deliver the ultrasoundenergy to the plurality of wood elements 238 a, 238 b, 238 c, 238 d, tothe filler material 248, or to both the plurality of wood elements 238a, 238 b, 238 c, 238 d and to the filler material 248. For clarity, theultrasound waves 236 depicted in FIG. 4 are shown emanating from theultrasound transducer 232 and above the plurality of wood elements 234,but the ultrasound waves 236 may also impact, be absorbed by, or passthrough one or more (e.g., two, three, or all) of the wood elements 238d, 238 c, 238 b, and 238 a.

The delivered ultrasound energy may provide, in some examples, amechanical stimulation to one or more of the plurality of wood elements238 a, 238 b, 238 c, 238 d. For example, as the ultrasound waves 236travel through a wood element or are absorbed by the wood element, theultrasound waves 236 may cause molecules within the wood element tovibrate. The vibration at the molecular level within the wood element(e.g., element 238 a, 238 b, 238 c, 238 d) may create friction betweenthe vibrating molecules, which can generate heat within the woodelement. Additionally, in some examples, as the ultrasound waves 236travel through or are absorbed by the wood element, the ultrasound waves236 may cause small or micro pressure differentials to be created withinthe wood element. Such pressure differentials can result in cavitationwithin the wood element, where micro-level gas or vapor bubbles may becreated within the wood element as gas or vapor from higher-pressureareas within the wood element are forced or pushed, due to the pressuredifferentials, toward lower-pressure areas within the wood element. Inone or more of these manners, the ultrasound energy may provide amechanical stimulation in the bonding of wood or other plant products,for example. This mechanical stimulation may be provided, for example,even though the ultrasound transducer 232 may not be in physical contactwith the wood elements 238 a, 238 b, 238 c, 238 d or with the fillermaterial 248. In some examples, the ultrasound transducer 232, or aportion of the transducer, may be in physical contact with one or moreof the wood elements 238 a, 238 b, 238 c, 238 d, with the fillermaterial 248, or with both the filler material 248 and one or more ofthe wood elements 238 a, 238 b, 238 c, 238 d, and the aforementionedmechanical stimulation may be provided.

The ultrasound energy may further provide a mechanical stimulation toone or more of the plurality of wood elements 238 a, 238 b, 238 c, 238 dat a macro level. For example, the mechanical stimulation provided bythe ultrasound waves 236 may cause one or more of the wood elements tomove or vibrate, for example, and such movement or vibration may createfriction between wood elements. For example, a surface of one of thewood elements may encounter resistance when moving, rubbing or vibratingin contact with one or more surfaces of another of the wood elements. Inone or more of these manners, the ultrasound energy may provide amechanical stimulation in the bonding of wood or other plant products,for example. This mechanical stimulation may be provided, for example,even though the ultrasound transducer 232 may not be in physical contactwith the wood elements 238 a, 238 b, 238 c, 238 d or with the fillermaterial 248. In some examples, the ultrasound transducer 232, or aportion of the transducer, may be in physical contact with one or moreof the wood elements 238 a, 238 b, 238 c, 238 d, with the fillermaterial 248, or with both the filler material 248 and one or more ofthe wood elements 238 a, 238 b, 238 c, 238 d, and the aforementionedmechanical stimulation may be provided.

In some examples, the ultrasound waves 236 may provide a mechanicalstimulation to the filler material 248. For example, as the ultrasoundwaves 236 travel through the filler material 248 or are absorbed by thefiller material 248, the ultrasound waves 236 may cause molecules withinthe filler material 248 to vibrate. The vibration at the molecular levelwithin the filler material 248 may create friction between the vibratingmolecules, which can generate heat within the filler material 248.Additionally, in some examples, as the ultrasound waves 236 travelthrough or are absorbed by the filler material 248, the ultrasound wavesmay cause small or micro pressure differentials to be created within thefiller material 248. Such pressure differentials can result incavitation within the filler material 248, where micro-level gas orvapor bubbles may be created within the filler material 248 as gas orvapor from higher-pressure areas within the filler material 248 areforced or pushed, due to the pressure differentials, to lower-pressureareas within the filler material 248. In one or more of these manners,the ultrasound energy may provide a mechanical stimulation in thebonding of wood or other plant products, for example. This mechanicalstimulation may be provided, for example, even though the ultrasoundtransducer 232 may not be in physical contact with the wood elements 238a, 238 b, 238 c, 238 d or with the filler material 248. In someexamples, the ultrasound transducer 232, or a portion of the transducer,may be in physical contact with one or more of the wood elements 238 a,238 b, 238 c, 238 d, with the filler material 248, or with both thefiller material 248 and one or more of the wood elements 238 a, 238 b,238 c, 238 d, and the aforementioned mechanical stimulation may beprovided.

The ultrasound energy may further provide, in some examples, amechanical stimulation to the filler material 248 at a macro level. Forexample, the mechanical stimulation provided by the ultrasound waves 236may agitate the filler material 248, and may cause the filler material248 to move, vibrate, diffuse, spread, flow, or penetrate, to list justa few examples. In one or more of these manners, the ultrasound energymay provide a mechanical stimulation in the bonding of wood or otherplant products, for example. This mechanical stimulation may beprovided, for example, even though the ultrasound transducer 232 may notbe in physical contact with the wood elements 238 a, 238 b, 238 c, 238 dor with the filler material 248. In some examples, the ultrasoundtransducer 232, or a portion of the transducer, may be in physicalcontact with one or more of the wood elements 238 a, 238 b, 238 c, 238d, with the filler material 238, or with both the filler material 238and one or more of the wood elements 238 a, 238 b, 238 c, 238 d, and theaforementioned mechanical stimulation may be provided.

In some examples, the ultrasound energy may stimulate diffusion of thefiller material 248, and may cause the filler material 248 to penetrateinto one or more of the wood elements 238 a, 238 b, 238 c, 238 d, ordeeper into one or more of the wood elements, for example. In someimplementations, the ultrasound energy may stimulate diffusion of thefiller material 248, and may cause the filler material to more broadlyspread across, cover, or contact one or more of the wood elements, forexample. In one or more of these manners, the ultrasound energy mayprovide a diffusional stimulation in the bonding of wood or other plantproducts. This diffusional stimulation may be provided, for example,even though the ultrasound transducer 232 may not be in physical contactwith the wood elements 238 a, 238 b, 238 c, 238 d or with the fillermaterial 248. In some examples, the ultrasound transducer 232, or aportion of the transducer, may be in physical contact with one or moreof the wood elements 238 a, 238 b, 238 c, 238 d, with the fillermaterial 248, or with both the filler material 248 and one or more ofthe wood elements 238 a, 238 b, 238 c, 238 d, and the aforementioneddiffusional stimulation may be provided.

The ultrasound energy may also, in some examples, provide a thermalstimulation to one or more of the plurality of wood elements 238 a, 238b, 238 c, 238 d, to the filler material 248, or to the plurality of woodelements and to the filler material, according to some implementations.This thermal stimulation may be in addition to any heat generated due tothe mechanical stimulation or stimulations described above, for example.In some implementations, a temperature of the one or more of the woodelements 238 a, 238 b, 238 c, 238 d may increase as the wood elementabsorbs the ultrasound energy, or a portion of the ultrasound energy.Similarly, a temperature of the filler material 248 may increase as thefiller material 248 absorbs the ultrasound energy, or a portion of theultrasound energy. The increase in temperature of the filler material,of the wood elements, or of both the filler material and one or more ofthe wood elements may stimulate better diffusion of the filler material248 in some examples, and may stimulate deeper penetration of the fillermaterial 248 into one or more of the wood elements 238 a, 238 b, 238 c,238 d, as by stimulating better flow of the filler material 248 (e.g.,in implementations where the filler material is a liquid or capable offlowing). In one or more of these manners, the ultrasound energy mayprovide a thermal stimulation in the bonding of wood or other plantproducts. This thermal stimulation may be provided, for example, eventhough the ultrasound transducer 232 may not be in physical contact withthe wood elements 238 a, 238 b, 238 c, 238 d or with the filler material248. In some examples, the ultrasound transducer 232, or a portion ofthe transducer, may be in physical contact with one or more of the woodelements 238 a, 238 b, 238 c, 238 d, with the filler material 248, orwith both the filler material 248 and one or more of the wood elements238 a, 238 b, 238 c, 238 d, and the aforementioned thermal stimulationmay be provided.

In some examples, friction generated between the wood elements (e.g.,between any of wood elements 238 a, 238 b, 238 c, 238 d) or between thefiller material 248 and one or more wood elements due to the applicationof the ultrasound energy can cause the filler material 248 to be pushedor driven into crevices, pores, gaps, spaces, voids, or cavities in oneor more of the wood elements 238 a, 238 b, 238 c, 238 d. In someimplementations, the friction may stimulate atomization of the fillermaterial 248 (e.g., cause the filler material 248 to be separated intosmaller or finer particles), which can in some examples stimulate thefiller material 248 to be pushed or driven into crevices, pores, gaps,spaces, voids or cavities in one or more of the wood elements. In someexamples, the friction may further generate heat, which may alsostimulate a deeper penetration by the filler material 248 into one ormore of the wood elements, for example by heating the filler material248 and stimulating better flow of the filler material 248 (e.g., inimplementations where the filler material is a liquid or capable offlowing). In one or more of these manners, the ultrasound energy maygenerate friction between the one or more of the wood elements 238 a,238 b, 238 c, 238 d or between the filler material 248 and the woodelements, which may provide a stimulation in the bonding of wood orother plant products. This stimulation may be provided, for example,even though the ultrasound transducer 232 may not be in physical contactwith the wood elements 238 a, 238 b, 238 c, 238 d or with the fillermaterial 248. In some examples, the ultrasound transducer 232, or aportion of the transducer, may be in physical contact with one or moreof the wood elements 238 a, 238 b, 238 c, 238 d, with the fillermaterial 248, or with both the filler material 248 and one or more ofthe wood elements 238 a, 238 b, 238 c, 238 d, and the aforementionedstimulation may be provided.

FIG. 4 depicts ultrasound transducer 232 delivering the ultrasound waves236 from a location generally above the plurality of wood elements 238a, 238 b, 238 c, 238 d, but in other examples the ultrasound transducer232 may deliver the ultrasound waves 236 from a location that isgenerally lateral of (e.g., generally left or right of), ahead of (e.g.,in front of as the wood elements approach), or behind the plurality ofwood elements, or from a location that is generally below the pluralityof wood elements 238 a, 238 b, 238 c, 238 d. In some examples, there maybe two or more (e.g., two, three, four, five, six, or more) ultrasoundtransducers 232 that may concurrently or at different times deliverultrasound waves to a plurality of wood elements. For example, someimplementations may include two or more ultrasound transducers 232 thatmay concurrently deliver ultrasound waves to a plurality of woodelements from locations generally above the plurality of wood elements.As another example, some implementations may include two or moreultrasound transducers 232 that may concurrently deliver ultrasoundwaves to a plurality of wood elements from locations generally lateralof, ahead of, behind, or under the plurality of wood elements. As yetanother example, some implementations may include one or more (e.g.,one, two, three, or more) ultrasound transducers 232 that mayconcurrently deliver ultrasound waves to a plurality of wood elementsfrom one or more locations generally above the plurality of woodelements, and also may include one or more (e.g., one, two, three, ormore) ultrasound transducers 232 that may concurrently deliverultrasound waves to a plurality of wood elements from one or morelocations generally lateral of, ahead of, behind, or under the pluralityof wood elements. Other combinations are also possible, as will beapparent to one of skill in the art.

FIG. 5 is a conceptual diagram 260 of the example ultrasound transducer232 of FIG. 4. The example ultrasound transducer 232 includes an examplehousing 262. Disposed within the housing 262 are one or more exampleultrasound energy generation elements 264, which may be disposed, forexample, between an example ground electrode 266 and an example positiveelectrode 268. In some examples, the one or more ultrasound energygeneration elements 264 are one or more piezoelectric transducers.Piezoelectric transducers, such as one or more piezoelectric crystals orpiezoelectric elements, for example, can utilize a piezoelectricproperty of the material to convert electric energy into mechanicalenergy. In some examples, the piezoelectric crystal or element mayinclude a piezoelectric ceramic material. In some examples, the one ormore ultrasound energy generation elements 264 are one or moremagnetostrictive transducers. Magnetostrictive transducers, such as oneor more coils of wire placed around one or more magnetostrictivematerials, for example, can produce a mechanical energy based on amagnetostrictive property of the magnetostrictive materials and amagnetic field that can be provided by the wire and the magnetostrictivematerials. Nickel, iron, and cobalt are a few examples ofmagnetostrictive materials.

The positive electrode 268 may be energized by an electrical conductor270 that may carry a live electrical signal with respect to anelectrical ground 272, and the ground electrode 266 may be electricallycoupled to the electrical ground 272. In some examples, the housing 262may also be electrically coupled to the electrical ground 272. In someexamples, each of the electrical conductor 270 and the electrical ground272 may be provided to the transducer 232 by a power cable 274.

The live electrical signal provided to the positive electrode 268 cancause an electrical current to flow between the positive electrode 268and the ground electrode 266. As the electrical current flows betweenthe positive electrode 268 and the ground electrode 266, the one or moreultrasound energy generation elements 264 may be excited by theelectrical current, as described generally above, and may generateultrasound waves.

The transducer 232 includes an example horn 276, sometimes also referredto as a sonotrode, which can direct the ultrasound waves toward a targetfor the ultrasound waves, such as a plurality of wood elements. In someexamples, one or more example matching layers 278 may be includedbetween the ground electrode 266 and an opening 280 defined in thehousing 262. The one or more matching layers 278 may include materialsthat are conducive to achieving a better energy transfer of theultrasound energy to the horn 276 and the target. Example materials thatcan be used for the one or more matching layers 278, for embodimentsthat include one or more matching layers 278, can include epoxy,polyurethane, polystyrene, and the like. One or more example backinglayers 282, located on an opposite side of the positive electrode 268from the one or more ultrasound energy generation elements 264, mayprevent ultrasound waves from propagating in a direction away from theopening 280 in the housing 262. Additionally, an example acousticinsulation layer 284, which may be generally disposed between aninternal surface of the housing 262 and the one or more backing layers282, may provide acoustic insulation to prevent or limit the escape ofultrasound waves from the transducer 232 other than by the opening 280via the horn 276.

In general, the ultrasound transducer 232 and horn 276 may have manydifferent shapes and topologies, depending on the implementation. Forexample, some ultrasound transducers may include two or more (e.g., two,three, four, or more) openings 280 in a housing of the transducer, sothat ultrasound waves generated by the transducer may impact one or moretargets from more than one position or direction. Some ultrasoundtransducers can have two or more sets of ultrasound energy generationelements (e.g., piezoelectric elements, magnetostrictive elements, orcombinations of the foregoing) and two or more sets of positive andground electrodes, for example.

FIGS. 6A-6H are diagrams of various implementations of ultrasoundtransducers, and include a variety of horn configurations. FIG. 6A is aconceptual diagram 300 of an example ultrasound transducer 302 thatincludes an example cymbal-shaped horn 304 that can be used formanufacturing composite wood products using ultrasound energy. As withpreviously described transducers, the ultrasound transducer 302 maygenerate ultrasound waves 306, which may be directed towards a target308 (e.g., a plurality of wood elements) via the horn 304. Thecymbal-shaped horn 304 may in some examples be shaped similarly to thecommon percussion instrument. In some examples, the cymbal-shaped horn304 may be shaped like a short cylinder, such as depicted in FIG. 6A.The horn 304 may define an opening 310 generally near a center of thehorn 304, and the ultrasound waves 306 may emanate from the opening 310.The cymbal-shaped horn 304 may act as an acoustic waveguide, forexample.

FIG. 6B is a conceptual diagram 320 of an example ultrasound transducer322 that includes an example Langevin horn 324 that can be used formanufacturing composite wood products using ultrasound energy. Theultrasound transducer 322 may generate ultrasound waves 326, which maybe directed towards a target 328 (e.g., a plurality of wood elements)via the horn 324. The Langevin horn 324 may define an opening 330, fromwhich the ultrasound waves 326 may emanate. The Langevin horn 324 mayact as an acoustic waveguide, for example.

FIG. 6C is a conceptual diagram 340 of an example ultrasound transducer342 that includes an example ring-shaped horn 344 that can be used formanufacturing composite wood products using ultrasound energy. Thering-shaped horn 344 defines a plurality of openings 346 in the horn.The ultrasound transducer 342 may generate ultrasound waves 348, whichmay emanate from the plurality of openings 346 defined by thering-shaped horn 344, and may be directed towards a target 350 (e.g., aplurality of wood elements) via the horn 344. The ring-shaped horn 344may act as an acoustic waveguide, for example. In some examples, theplurality of openings 346 may be defined on an underside of thering-shaped horn 344, for example for implementations where thering-shaped horn 344 is generally located above the target. In someexamples, the plurality of openings 346 may be defined on a top side ofthe ring-shaped horn 344, for example for implementations where thering-shaped horn 344 is generally located under the target. In someexamples, the plurality of openings 346 may be defined on aninward-facing surface of the ring-shaped horn 344, for example forimplementations where the target, or a portion of the target, is locatedinterior of a space defined by the ring-shaped horn 344. In someexamples, openings 346 may be defined on a combination of theaforementioned ring-location possibilities.

FIG. 6D is a conceptual diagram 360 of an example ultrasound transducer362 that includes an example pyramid-shaped horn 364 that can be usedfor manufacturing composite wood products using ultrasound energy. Theultrasound transducer 362 may generate ultrasound waves 366, which maybe directed towards a target 368 (e.g., a plurality of wood elements)via the horn 364. In the depicted example of FIG. 6D, the pyramid-shapedhorn 364 includes four sides, and the base of the pyramid has a squareor rectangular shape. In various examples, the pyramid-shaped horn mayhave any appropriate number of sides (e.g., three, four, five, six, ormore). The horn 364 may define an opening 370 generally near a center ofthe horn 364, and the ultrasound waves 366 may emanate from the opening370. The pyramid-shaped horn 364 may act as an acoustic waveguide, forexample.

FIG. 6E is a conceptual diagram 380 of an example ultrasound transducer382 that includes an example sphere-shaped horn 384 that can be used formanufacturing composite wood products using ultrasound energy. Theultrasound transducer 382 may generate ultrasound waves 386, which mayradiate from the sphere-shaped horn 384 and be directed towards a target388 (e.g., a plurality of wood elements) via the horn 384. Thesphere-shaped horn 384 may have any appropriate diameter. Thesphere-shaped horn 384 may act as an acoustic waveguide, for example.

FIG. 6F is a conceptual diagram 400 of an example ultrasound transducer402 that includes an example dome-shaped horn 404 that can be used formanufacturing composite wood products using ultrasound energy. Theultrasound transducer 402 may generate ultrasound waves 406, which maybe directed towards a target 408 (e.g., a plurality of wood elements)via the horn 404. The horn 404 may define an opening 410 generally neara center of the horn 404, and the ultrasound waves 406 may emanate fromthe opening 410. The dome-shaped horn 404 may act as an acousticwaveguide, for example. Although not depicted in FIG. 6 for brevity, insome examples the dome-shaped horn 404 may be inverted with respect toits depicted orientation to the ultrasound transducer 402 in FIG. 6F.For example, in some implementations the horn may be shaped like asaucer or a cup.

FIG. 6G is a conceptual diagram 420 of an example ultrasound transducer422 that includes an example wedge-shaped horn 424 that can be used formanufacturing composite wood products using ultrasound energy. Theultrasound transducer 422 may generate ultrasound waves 426, which maybe directed towards a target 428 (e.g., a plurality of wood elements)via the horn 424. In the depicted example of FIG. 6G, the wedge-shapedhorn 424 includes four sides, and the base of the wedge has arectangular shape. In various examples, the wedge-shaped horn may haveany appropriate number of sides (e.g., three, four, five, six, or more).The horn 424 may define a slot-shaped opening 430, and the ultrasoundwaves 426 may emanate from the opening 430. The wedge-shaped horn 424may act as an acoustic waveguide, for example.

FIG. 6H is a conceptual diagram 440 of an example ultrasound transducer442 that includes an example horn 444, generally shaped as a tube or acylinder in FIG. 6H, that can be used for manufacturing composite woodproducts using ultrasound energy, where the horn 444 includes an examplechamber 446. In various examples, the chamber 446 may define a spacewithin the horn 444 where various elements or materials, after beingintroduced to the chamber 446, may be sonicated within the horn 444, forexample. The chamber 446 may have any appropriate number of inputchannels, which may be used to feed elements or materials into thechamber 446, for example. Chamber 446 includes two input channels: anexample first input channel 448 (labeled “Input A” in FIG. 6H) and anexample second input channel 450 (labeled “Input B” in FIG. 6H); inother examples the chamber 446 may include one, three, four, or moreinput channels. Examples of elements or materials that may be introducedvia an input channel to the chamber 446 can include one or more types ofwood elements, one or more types of filler material (e.g., any of thetypes of filler material discussed herein), or combinations of theforegoing, to list just a few examples.

In some examples, a plurality of wood elements 452 (e.g., sawdust, woodflakes, wood chips, wood scraps, or the like) may be input to thechamber 446 via, for example, the first input channel 448, and a fillermaterial 454 may be input to the chamber 446 via the second inputchannel 450. The plurality of wood elements 452 and the filler material454 may be impacted by ultrasound waves 456 within the chamber 446,where the ultrasound waves 456 are generated by the ultrasoundtransducer 442. In some examples, the filler material 454 may adhere toor coat the plurality of wood elements 452 within the chamber 446, andthe ultrasound waves 456 within the chamber 446 may provide one or moreof mechanically stimulating and thermally stimulating the plurality ofwood elements 452 and the filler material 454 within the chamber 446,and may also stimulate diffusion of the filler material 454 onto andinto the wood elements 452, for example, as described above withreference to beneficial impacts that ultrasound may have.

The wood elements 452 and filler material 454 may be extruded from thehorn 444 and may be directed towards a target 458 (e.g., a plurality ofwood elements). Ultrasound waves 460, generated by the ultrasoundtransducer 442, may also be directed toward the target 458 via the horn444. The horn 444 may act as an acoustic waveguide, for example.

While FIG. 6H depicts the horn 444 as having a tubular or cylindricalshape, any of the horn shapes discussed herein may also include achamber similar to chamber 446, through which various elements ormaterials may pass and may be sonicated as they pass through thechamber. In some examples, a horn and chamber may be sized toaccommodate larger wood elements, such as one or more of wood strips,wood strands, wood veneers, and wood sheets, for example.

In some examples, any of the ultrasound transducers discussed herein maysimilarly include a chamber through which elements or materials may passand be sonicated, in some examples without using a horn. In someexamples, a horn can also be used with a transducer that includes achamber for sonicating elements or materials within the transducerchamber.

FIG. 7 is a flowchart 500 of an example method that can be used tomanufacture a composite wood product. At a first step 502, a fillermaterial is applied to a plurality of wood elements. The filler materialmay be applied by one or more applicators, such as any of theapplicators 158, 188, 208 shown in FIGS. 3A, 3B, and 3C, for example, orany of the other examples of applicators described herein. In someimplementations, the filler material may include an adhesive. In someimplementations, the filler material may not include an adhesive. Insome implementations, the filler material may include a plastic, whilein other implementations the filler material may not include a plastic.In some implementations, the filler material may include a metal, whilein other implementations the filler material may not include a metal.Combinations of the foregoing are also possible (e.g., filler materialincludes an adhesive and a plastic; filler material includes an adhesiveand a metal; or filler material includes an adhesive, plastic, andmetal). In some implementations, the filler material may be a liquid. Insome implementations, the filler material may be a solid. In someimplementations, the filler material may be a gas. Combinations of theforegoing examples of states of the filler material or filler materialscan also be used, according to some implementations. For example, insome implementations, the filler material may be a combination or amixture of a liquid and a solid. In some implementations, the fillermaterial may be a combination or a mixture of a liquid and a gas. Insome implementations, the filler material may be a combination or amixture of a solid and a gas. In some implementations, the fillermaterial may be a combination or a mixture of a liquid, a solid, and agas.

At step 504, the plurality of wood elements are bonded into a compositewood product, including delivering ultrasound energy with a frequencywithin a range of 10 kHz-20 MHz to the plurality of wood elements. Theultrasound energy may be delivered to the plurality of wood elements byone or more ultrasound transducers, such as the ultrasound transducer232 of FIG. 4, for example, or any of the other examples of ultrasoundtransducers described herein. In some examples, the ultrasound energydelivered to the plurality of wood elements may have a frequency withina range of 15 kHz-1 MHz. In some examples, the ultrasound energydelivered to the plurality of wood elements may have a frequency withina range of 20 kHz-100 kHz. In some examples, prior to the bonding of theplurality of wood elements, the plurality of wood elements may bearranged in a proximity to one another.

In some examples, the filler material is applied to the plurality ofwood elements prior to the delivery of the ultrasound energy to theplurality of wood elements. In some examples, the filler material isapplied to the plurality of wood elements concurrently with the deliveryof the ultrasound energy to the plurality of wood elements. In someexamples, the ultrasound energy is delivered to the plurality of woodelements prior to the application of the filler material to theplurality of wood elements.

FIG. 8 is a block diagram of an example environment 550 formanufacturing composite wood products using ultrasound energy. Invarious implementations, examples of the composite wood products caninclude, without limitation, girders, beams, joists, I-joists, rafters,headers, studs, trusses, columns, rim boards, plywood, particle board,fibreboard, oriented strand board, flakeboard, waferboard, chipboard,laminated timber, laminated veneer lumber, cross-laminated timber,parallel strand lumber, laminated strand lumber, and finger joints. Theenvironment 550 includes the filler material application area 104 andthe ultrasound energy delivery area 106, each described above withreference to FIG. 1 and other figures, and includes a compression forceapplication area 552. Although not shown in FIG. 8 for brevity, it willbe understood that in some implementations the wood element preparationarea 102 of FIG. 1 may also be included in environment 550.

The compression force application area 552 can be used to apply acompressive force to the plurality of wood elements. In some examples, apress can be used to apply a physical compression force to the pluralityof wood elements. FIG. 9 is a conceptual diagram of an exampleenvironment 580 for manufacturing composite wood products usingultrasound energy. The environment 580 includes an example fillermaterial applicator 582, example ultrasound transducers 584 a, 584 b,586 a, 586 b and an example press 588. Filler material applicator 582can apply a filler material to a plurality of wood elements 590, in amanner similar to that described above with reference to applicator 188of FIG. 3B. In the depicted example of FIG. 9, the applicator 582 is aroller element, but any of the other types of applicators (e.g., one ormore spray nozzles, brushes, rollers, or other types of applicators)described herein may alternatively be used.

A plurality of wood elements 594 may be arranged in proximity to oneanother. For example, a plurality of wood elements 594 may be stackedvertically, as described herein above, or may be arranged in anyappropriate manner. In some examples, the plurality of wood elements 594includes one or more elements 592 that have had filler material appliedthereto by applicator 582. In some examples, the plurality of woodelements 594 includes one or more wood elements 592 that have had fillermaterial applied thereto, and one or more wood elements that have nothad filler material applied thereto. And in some examples, the pluralityof wood elements 594 do not include filler material.

One or more ultrasound transducers may deliver ultrasound energy to theplurality of wood elements 594. In the example of FIG. 9, ultrasoundtransducers 584 a and 584 b are disposed laterally of a conveyor 595, onwhich the plurality of wood elements 594 may be transported, andlaterally of the plurality of wood elements when the plurality of woodelements are positioned in a target position 596 to receive ultrasoundenergy. A first ultrasound transducer 584 a is located to the left ofthe conveyor 595, and a second ultrasound transducer 584 b is located tothe right of the conveyor 595. Additionally, in this example, ultrasoundtransducers 586 a and 586 b are disposed above the conveyor 595, andabove the plurality of wood elements 594 when the plurality of woodelements are positioned in the target position 596 to receive ultrasoundenergy. In this example, the conveyor 595 may move the plurality of woodelements 594 into the target position 596 with respect to the ultrasoundtransducers, and the ultrasound transducers 584 a and 584 b may deliverultrasound energy to the plurality of wood elements 594 from positionslaterally left and laterally right of the wood elements, respectively,in rightward and leftward directions, respectively. Similarly, theultrasound transducers 586 a and 586 b may deliver ultrasound energy tothe plurality of wood elements 594 from above, in a downward direction.

In other examples, additional ultrasound transducers (e.g., five, six,seven, eight, or more), or fewer ultrasound transducers (e.g., one, two,or three) may be used. In some examples, ultrasound energy may beprovided from only one direction (e.g., only in a downward direction,from one or more ultrasound transducers generally above the plurality ofwood elements, or in any other direction), and in these examples, moreor fewer ultrasound transducers may be used than are shown in FIG. 9(e.g., transducers 584 a and 584 b may not be used). In some examples,ultrasound energy may be provided from two directions (e.g., in adownward direction, and in a first lateral direction, or in upward anddownward directions, or in left and right directions, or any othercombination), and in these examples, more or fewer ultrasoundtransducers may be used than are shown in FIG. 9. In the example of FIG.9, ultrasound energy is provided generally from three directions: in adownward direction from above (e.g., from ultrasound transducers 586 aand 586 b), in a first lateral direction (e.g., from ultrasoundtransducer 584 a), and in a second lateral direction (from ultrasoundtransducer 584 b). In some examples, ultrasound energy may be deliveredto the plurality of wood elements from more than three directions (e.g.,four, five, six, or more directions). For example, additional ultrasoundtransducers (not shown in FIG. 9 for brevity) may be provided to deliverultrasound energy to the wood elements in a rearward direction (e.g.,from a position ahead of, or in front of, the wood elements), in aforward direction (e.g., from a position trailing, or behind, the woodelements), or in an upward direction (e.g., from a position below, orbeneath, the wood elements). Of course, any of these alternativeultrasound transducer locations or configurations may also be utilizedin a system that delivers ultrasound energy to the plurality of woodelements from a single direction, from two directions, from threedirections, or from more than three directions.

In some examples, one or more of the depicted ultrasound transducers 584a, 584 b, 586 a, 586 b may be moved or repositioned to deliverultrasound energy to the wood elements from one or more of these otherdirections or positions, according to some implementations. While theultrasound transducers discussed above with reference to FIG. 9 aredepicted in the environment 580 that includes the press 588, it will beunderstood that any of the ultrasound transducers, or configurations,described with reference to FIG. 9 or elsewhere herein may be used inimplementations that do not include a press, or in implementations thatdo not include a compression force application area.

In some examples, the conveyor 595 may stop for a period of time whilethe ultrasound transducers deliver the ultrasound energy to theplurality of wood elements 594. In some examples, the conveyor 595 maycontinue to move while the ultrasound transducers deliver the ultrasoundenergy to the plurality of wood elements 594. In some examples, a speedof the conveyor 595 may be adjusted (e.g., slowed down) for a period oftime while the ultrasound transducers deliver the ultrasound energy tothe plurality of wood elements 594. In some examples, one or more of theultrasound transducers may be generally stationary with respect to themovement of the conveyor 595. In some examples, one or more of theultrasound transducers can be configured to move, for example to movewith respect to the conveyor 595, to move with respect to the targetposition 596, or to move with respect to the plurality of wood elements594.

The press 588 may deliver one or more compressive forces to theplurality of wood elements 594. In some examples, the press 588 maydeliver a downward compressive force to the plurality of wood elements594. In some examples, the press 588 may deliver one or more lateralcompressive forces (e.g., a compressive force from the left, acompressive force from the right, or compressive forces from both theleft and the right). In some examples, the press 588 may deliver acompressive force from the front of the plurality of wood elements 594,from the rear of the plurality of wood elements 594, or from both thefront and the rear of the plurality of wood elements 594. Combinationsof such applied compressive forces are also possible. For example,according to some implementations the press 588 may deliver a downwardcompressive force to the plurality of wood elements 588, and one or moreadditional compressive forces (e.g. a compressive force from the left,from the right, from both the left and the right, from the front, fromthe back, from both the front and the back, from each of the left,right, front, and back, or others). In some examples, the press 588 maybe generally stationary with respect to the movement of the conveyor595. In some examples, the press 588 can be configured to move withrespect to the conveyor 595, to move with respect to a target position597 to receive a compression force for the wood elements, or to movewith respect to the plurality of wood elements 594.

In some examples, ultrasound energy may be delivered to the plurality ofwood elements, and thereafter a compressive force may be applied to theplurality of wood elements. For example, according to someimplementations the conveyor 595 may generally move in a first direction598, and the one or more ultrasound transducers (transducers 584 a, 584b, 586 a, 586 b in the example of FIG. 9) may deliver ultrasound energyto the plurality of wood elements prior to the one or more presses(e.g., press 588 in the example of FIG. 9) delivering one or morecompressive forces to the plurality of wood elements. In some examples,one or more compressive forces may be applied to the plurality of woodelements, and thereafter ultrasound energy may be delivered to theplurality of wood elements. For example, according to someimplementations the conveyor 595 may generally move in a seconddirection 599, and the one or more presses (e.g., press 588 in theexample of FIG. 9) may apply one or more compressive forces to theplurality of wood elements prior to the one or more ultrasoundtransducers (e.g., transducers 584 a, 584 b, 586 a, 586 b in the exampleof FIG. 9) delivering ultrasound energy to the plurality of woodelements. Filler material may be applied to the plurality of woodelements prior to applying the compressive force and delivering theultrasound energy in each of the preceding two examples, according tosome implementations.

In some examples, one or more ultrasound transducers can be integralwith the press, and can deliver ultrasound energy to the plurality ofwood elements concurrently with (or prior to, after, or a combination ofthe foregoing, depending on the implementation) the press delivering oneor more compressive forces to the plurality of wood elements. FIG. 10Ais a conceptual diagram 600 of an example press 602 and an exampleultrasound transducer 604 that is integral with the press 602, and thatcan be used for manufacturing composite wood products using ultrasoundenergy. The ultrasound transducer 604 and the press 602 mayrespectively, in some implementations, concurrently deliver ultrasoundenergy and a compressive force to a plurality of wood elements 606. Theexample of FIG. 10A shows wood elements 606 (two wood veneers stackedvertically in this example, but any of the wood elements discussedherein could alternatively be used) on a conveyor 608, which may movethe plurality of wood elements 606 into a target position 609 beneaththe press 602 and ultrasound transducer 604.

The press 602 may apply a downward compressive force 610 to theplurality of wood elements 606 when the wood elements 606 are in thetarget position 609, and the ultrasound transducer 604 may concurrentlydeliver ultrasound energy to the plurality of wood elements. The press602 includes a surface 612 that can apply the force 610 to the pluralityof wood elements 606. In some examples, the ultrasound transducer 604can be arranged flush with the surface 612 of the press 602 that canapply the compressive force 610 to the plurality of wood elements 606.In some examples, the ultrasound transducer 604 can be arranged to berecessed with respect to the surface 612 of the press 602 that can applythe compressive force 610 to the plurality of wood elements 606. In thisexample, the press 602 and the ultrasound transducer 604 can provide thecompressive force and the ultrasound energy, respectively, in a firstdirection (e.g., downward in this example with respect to the targetposition 609). In some examples, the press 602 and the ultrasoundtransducer 604 may respectively deliver the compressive force and theultrasound energy at different times. For example, the ultrasoundtransducer 604 may first deliver ultrasound energy to the plurality ofwood elements, and the press 602 may thereafter apply a compressiveforce to the plurality of wood elements. Alternatively, the press 602may first apply a compressive force to the plurality of wood elements,and the ultrasound transducer 604 may thereafter deliver ultrasoundenergy to the plurality of wood elements. In some examples, the press602 and the ultrasound transducer 604 may respectively deliver thecompressive force and the ultrasound energy concurrently, and also atdifferent times.

FIG. 10B is a conceptual diagram 620 of an example press 622 and one ormore example ultrasound transducers 624 a, 624 b that are integral withthe press 622, and that can be used for manufacturing composite woodproducts using ultrasound energy. The ultrasound transducers 624 a, 624b and the press 622 may respectively and concurrently, in someimplementations, deliver ultrasound energy and one or more compressiveforces to a plurality of wood elements 626. The example of FIG. 10Bshows four ultrasound transducers 624 a that are integral with the press622 and that are arranged to deliver ultrasound energy in a firstdirection (e.g., in a downward direction from a position above theplurality of wood elements in this example) toward the plurality of woodelements 626 when the plurality of wood elements 626 is in a targetposition 627. The example of FIG. 10B shows one ultrasound transducer624 b that is integral with the press 622 and is arranged to deliverultrasound energy from a second direction (e.g., in a lateral direction,leftward from a position right of the plurality of wood elements in thisexample) toward the plurality of wood elements 626 when the plurality ofwood elements 626 is in the target position 627. The example of FIG. 10Bshows wood elements 626 (four wood sheets, arranged 2×2 (two-high bytwo-wide), but any of the wood elements discussed herein couldalternatively be used) on a conveyor 628, which may move the pluralityof wood elements 626 into the target position 627.

The press 622, in this example, may apply a downward compressive force630 to the plurality of wood elements 626, for example when theplurality of wood elements 626 are in the target position 627. The press622 includes a first surface 631 that can apply the downward compressiveforce 630 to the plurality of wood elements 626. The press 622 may alsoapply, in this example, a lateral compressive force 632 to the pluralityof wood elements 626, for example when the plurality of wood elements626 are moved in the target position 6. In this example, the lateralcompressive force 632 may be a leftward compressive force applied by thepress 622 from the right of the plurality of wood elements 626 when theplurality of wood elements are located in the target position 627. Thepress 602 includes a second surface 633 that can apply the lateral force632 to the plurality of wood elements 626. In some examples, the lateralcompressive force may be a rightward compressive force applied by thepress 622 (using a surface of the press opposite the second surface 633in FIG. 10B, for example) from the left of the plurality of woodelements 626 when the plurality of wood elements are located in thetarget position 627. In some examples, two lateral compressive forcesmay be applied by the press 622. For example, both a leftward lateralcompressive force and a rightward lateral force may be applied by thepress 622, according to some implementations.

In some examples, the press 622 can apply one or more downward forces(e.g., force 630) and one or more lateral forces (e.g., force 632, orother lateral forces described above) concurrently. In some examples,the press 622 can apply one or more downward forces and one or morelateral forces at different times. For example, the press 622 may firstapply the downward force 630, and then may apply the lateral force 632(or other lateral forces). As another example, the press 622 may firstapply the lateral force 632 (or other lateral forces), and then mayapply the downward force 630.

In some examples, the ultrasound transducers 624 a can be arranged flushwith the first surface 631 of the press 622 that can apply the downwardcompressive force 630 to the plurality of wood elements 626. In someexamples, the ultrasound transducers 624 a can be arranged to berecessed with respect to the first surface 631 of the press 622.Similarly, in some examples the ultrasound transducer 624 b can bearranged flush with the second surface 633 of the press 622 that canapply the lateral compressive force 632 to the plurality of woodelements 626, and in some examples the ultrasound transducer 624 b canbe arranged to be recessed with respect to the second surface 633. Inthis example, the press 622 and the ultrasound transducers 624 a, 624 bcan provide the one or more compressive forces 630, 632 and theultrasound energy, respectively, in a first direction (e.g., downward inthis example with respect to the target position 627) and in a seconddirection (e.g., laterally in this example with respect to the targetposition 627). In some examples, the press 622 and the ultrasoundtransducers 624 a, 624 b may respectively deliver the one or morecompressive forces and the ultrasound energy at different times, forexample in manners similar to those discussed above with reference toFIG. 10A.

FIG. 10C is a conceptual diagram 640 of an example press 642 and one ormore example ultrasound transducers 644 a, 644 b that are integral withthe press 642, and that can be used for manufacturing composite woodproducts using ultrasound energy. The ultrasound transducers 644 a, 644b and the press 642 may respectively and concurrently, in someimplementations, deliver ultrasound energy and one or more compressiveforces to a plurality of wood elements 646. The example of FIG. 10Cshows three ultrasound transducers 644 a that are integral with thepress 642 and that are arranged to deliver ultrasound energy in a firstdirection (e.g., in a downward direction from a position above theplurality of wood elements in this example) toward the plurality of woodelements 646 when the plurality of wood elements 646 is in a targetposition 647. The example of FIG. 10C shows three ultrasound transducers644 b that are integral with the press 642 and are arranged to deliverultrasound energy from a second direction (e.g., in a rearward directionfrom a position forward of the plurality of wood elements 646 when thewood elements are in the target position 647) toward the plurality ofwood elements 646. The example of FIG. 10C shows wood elements 646 (fourwood strips, arranged 2×2 (two-high by two-wide), but any of the woodelements discussed herein could alternatively be used) on a conveyor648, which may move the plurality of wood elements 646 into the targetposition 647.

The press 642, in this example, may apply a downward compressive force650 to the plurality of wood elements 646, for example when theplurality of wood elements 646 are in the target position 647. The press642 includes a first surface 651 that can apply the downward force 650to the plurality of wood elements 646. The press 642 may also apply, inthis example, a rearward compressive force 652 to the plurality of woodelements 646, for example when the plurality of wood elements 646 are inthe target position 647. In this example, the rearward compressive force652 may be applied by the press 622 from a position forward of theplurality of wood elements 646 when the plurality of wood elements arelocated in the target position 647. The press 642 includes a secondsurface 653 that can apply the rearward compressive force 652 to theplurality of wood elements 646. In some examples, the press may apply aforward compressive force (e.g., using a surface of the press oppositethe second surface 653 in FIG. 10C) from a position behind the pluralityof wood elements 646 when the plurality of wood elements is located inthe target position 647. In some examples, the press 622 may apply botha rearward force and a forward force to the plurality of wood elements.

In some examples, the press 642 can apply one or more downward forces(e.g., force 650) and one or more other forces (e.g., force 652, orother forces described above) concurrently. In some examples, the press642 can apply one or more downward forces and one or more other force atdifferent times. For example, the press 642 may first apply the downwardforce 650, and then may apply the rearward force 652 (or a forwardforce, or other forces). As another example, the press 642 may firstapply the rearward force 652 (or the forward force, or other forces),and then may apply the downward force 650.

In some examples, the ultrasound transducers 644 a can be arranged flushwith the first surface 651 of the press 642 that can apply the downwardcompressive force 650 to the plurality of wood elements 646. In someexamples, the ultrasound transducers 644 a can be arranged to berecessed with respect to the first surface 651 of the press 642.Similarly, in some examples the ultrasound transducers 644 b can bearranged flush with the second surface 653 of the press 642 that canapply the rearward compressive force 652 to the plurality of woodelements 646, and in some examples the ultrasound transducers 644 b canbe arranged to be recessed with respect to the second surface 653. Inthis example, the press 642 and the ultrasound transducers 644 a, 644 bcan provide the one or more compressive forces 650, 652 and theultrasound energy, respectively, in a first direction (e.g., downward inthis example with respect to the target position 647) and in a seconddirection (e.g., rearward in this example with respect to the targetposition 647). In some examples, the press 642 and the ultrasoundtransducers 644 a, 644 b may respectively deliver the one or morecompressive forces and the ultrasound energy at different times, forexample in manners similar to those discussed above with reference toFIG. 10A.

The examples of FIGS. 10B and 10C show that ultrasound energy can bedelivered to a plurality of wood elements from two or more directions,according to some implementations. For example, the examples of FIGS.10B and 10C show that ultrasound energy can be delivered to a pluralityof wood elements in a downward direction (e.g., from a positiongenerally above the plurality of wood elements) and in another directiondifferent from the downward direction (e.g., in a lateral direction,such as from a position left-of or right-of the wood elements; in arearward direction, such as from a location forward of the woodelements; and in a forward direction, such as from a location rearwardof the wood elements).

FIG. 11A is a block diagram of an example environment 670 formanufacturing composite wood products using ultrasound energy. Theenvironment 670 includes the filler material application area 104 andthe ultrasound energy delivery area 106, each described above withreference to FIG. 1 and other figures, including the components that canbe included in areas 104 and 106, and also includes a defect inspectionarea 672. In some examples, after the plurality of wood elements hasbeen bonded into a composite wood product, the composite wood productmay be inspected for defects, which may occur in the defect inspectionarea 672. In various implementations, the inspecting for defects caninclude delivering ultrasound energy to the composite wood product. Thisadditional delivery of ultrasound energy may be delivered, in someexamples, by the same ultrasound transducer or transducers thatdelivered the ultrasound energy to the plurality of wood elements in thebonding of the wood elements. In some examples, this additional deliveryof ultrasound energy may be delivered by one or more ultrasoundtransducers different from those that delivered the ultrasound energy tothe plurality of wood elements in the bonding of the wood elements.

The defect inspection area 672 may include a defect inspection componentthat may deliver ultrasound energy (e.g., via one or more ultrasoundtransducers) to the composite wood product, and may inspect the productfor a defect. In some examples, the defect inspection component mayinclude one or more cameras. In some examples, the ultrasound energy maybe delivered by one or more ultrasound transducers that are separatefrom the defect inspection component. Although not shown in FIG. 11A forbrevity, it will be understood that in some implementations one or moreof the compression force application area 552 of FIG. 8 and the woodelement preparation area 102 of FIG. 1 may also be included inenvironment 670.

FIG. 11B is a block diagram of an example environment 680 formanufacturing composite wood products using ultrasound energy. Theenvironment 680 includes the filler material application area 104 andthe ultrasound energy delivery area 106, each described above withreference to FIG. 1 and other figures, including the components that canbe included in areas 104 and 106, and also includes a composite woodproduct treatment area 682. In some examples, after the plurality ofwood elements has been bonded into a composite wood product, a treatmentmay be applied to the composite wood product, which may occur in thecomposite wood product treatment area 682.

In various implementations, the treatment application to the compositewood product can include delivering ultrasound energy to the compositewood product. This additional delivery of ultrasound energy may bedelivered, in some examples, by the same ultrasound transducer ortransducers that delivered the ultrasound energy to the plurality ofwood elements in the bonding of the wood elements. In some examples,this additional delivery of ultrasound energy may be delivered by one ormore ultrasound transducers different from those that delivered theultrasound energy to the plurality of wood elements in the bonding ofthe wood elements.

Examples of treatments that can be applied to the composite woodproducts can include one or more sealants, flame-retardant treatments,insect- or vermin-repellant treatments, stains, paints, or otherpost-treatments, and as described such treatment can also includedelivery of ultrasound energy to the composite wood product. In someexamples, an edging treatment may be applied to the composite woodproduct, and as described such treatment can also include delivery ofultrasound energy to the composite wood product. In some examples, theultrasound energy may provide one or more benefits with reference to thetreatment similar to those described above with reference to the fillermaterial. For example, the ultrasound energy may stimulate diffusionacross or penetration of the treatment into, or deeper into, thecomposite wood product, or may stimulate better flow of the treatmentfor treatments that are liquid or capable of flowing.

The composite wood product treatment area 682 may include a treatmentdelivery component, which may apply the treatment to the composite woodproduct. In some examples, the treatment application component mayinclude one or more of rollers, brushes, spray applicators, or the like.In some examples, the treatment application component can deliverultrasound energy (e.g., via one or more ultrasound transducers) to thecomposite wood product. In some examples, the ultrasound energy may bedelivered by one or more ultrasound transducers that are separate fromthe treatment application component. Although not shown in FIG. 11B forbrevity, it will be understood that in some implementations one or moreof the compression force application area 552 of FIG. 8, the woodelement preparation area 102 of FIG. 1, and the defect inspection area672 of FIG. 11A may also be included in environment 680.

FIG. 11C is a block diagram of an example environment 690 formanufacturing composite wood products using ultrasound energy. Theenvironment 690 includes the filler material application area 104 andthe ultrasound energy delivery area 106, each described above withreference to FIG. 1 and other figures, including the components that canbe included in areas 104 and 106, and also includes a pretreatment area692. In some examples, before applying filler material to the pluralityof wood elements, a pretreatment that includes delivery of ultrasoundenergy to the plurality of wood elements may be applied to the pluralityof wood elements, which may occur in the pretreatment area 692. In someexamples, such pretreatment with ultrasound energy may clean the woodelements. For example, the cleaning may help to remove dirt or otherimpurities from the wood elements. The pretreatment area 692 may includea pretreatment delivery component. The pretreatment of wood elements mayinclude delivering ultrasound energy at a lower ultrasound energy levelthan the ultrasound energy level used in bonding the plurality of woodelements, according to some implementations. For example, one or moreultrasound transducers may deliver ultrasound energy to the plurality ofwood elements as a pretreatment of the plurality of wood elements. Thispretreatment delivery of ultrasound energy may be delivered, in someexamples, by the same ultrasound transducer or transducers that willdeliver the ultrasound energy to the plurality of wood elements in thebonding of the wood elements. In some examples, this pretreatmentdelivery of ultrasound energy may be delivered by one or more ultrasoundtransducers different from those that will deliver the ultrasound energyto the plurality of wood elements in the bonding of the wood elements.Although not shown in FIG. 11C for brevity, it will be understood thatin some implementations one or more of the compression force applicationarea 552 of FIG. 8, the wood element preparation area 102 of FIG. 1, thedefect inspection area 672 of FIG. 11A, and the composite wood producttreatment area 682 of FIG. 11B may also be included in environment 690.

In some examples, an ultrasound transducer that includes a rollerelement can be used to deliver ultrasound energy to a plurality of woodelements. The roller element may have various shapes and sizes,depending on the implementation. For example, in some implementations,the roller element may include a cylindrical body. In someimplementations, the roller element may include a spherical body. Insome examples, the body of the roller element may include an outersurface configured to physically contact the plurality of wood elementsduring delivery of the ultrasound energy. In some examples, the body ofthe roller element may include an outer surface configured to physicallycontact and roll across the plurality of wood elements during deliveryof the ultrasound energy. In some examples, the outer surface of thebody of the roller element may be substantially smooth. In someexamples, the outer surface of the body of the roller element mayinclude a plurality of protrusions. In some examples, the outer surfaceof the body of the roller element may include a plurality of recessedfeatures. In some examples, the outer surface of the body of the rollerelement may include one or more protrusions and one or more recessedfeatures.

FIG. 12A is a conceptual diagram of an example environment 700 formanufacturing composite wood products using ultrasound energy, where theexample environment 700 includes an example ultrasound transducer 704that includes an example roller element 706. The environment 700includes example filler material applicators 702, an example ultrasoundtransducer 704, and an example roller element 706. Filler materialapplicators 702 can apply a filler material to a plurality of woodelements 708, in a manner similar to that described above with referenceto applicators 158 of FIG. 3A. In the depicted example of FIG. 12A, theapplicators 702 are spray nozzles, but any of the other types ofapplicators (e.g., one or more brushes, rollers, or other types ofapplicators) described herein may alternatively be used.

A plurality of wood elements 710 may be arranged in proximity to oneanother. For example, a plurality of wood elements 710 may be stackedvertically and arranged laterally, or may be arranged in any appropriatemanner. In the depicted example of FIG. 12A, the wood elements, whichmay be wood veneers in this example, are arranged 2×2. In some examples,the plurality of wood elements 710 includes one or more elements 712that have had filler material applied thereto by the applicators 702. Insome examples, the plurality of wood elements 710 includes one or moreelements 712 that have had filler material applied thereto, and one ormore wood elements that have not have filler material applied thereto.And in some examples, the plurality of wood elements 710 does notinclude filler material. The plurality of wood elements 710 may bearranged on a conveyor 714, and may travel in a direction 716 on theconveyor 714. The conveyor 714 may move the plurality of wood elements710 into a target position 717 with respect to the ultrasound transducer704, with respect to the roller element 706, or with respect to both theultrasound transducer 704 and the roller element 706.

Ultrasound energy may be generated by the ultrasound transducer 704, andmay be delivered to the plurality of wood elements 710 via the rollerelement 706, according to some examples. The ultrasound energy may beguided from the ultrasound transducer 704 to the roller element 706 byan example ultrasound horn 718, which may be coupled to the ultrasoundtransducer 704 and may be configured to guide the ultrasound energy fromthe transducer 704 to the roller element 706. The roller element 706 mayrotate about an axis, such as an axel 720, which may couple the rollerelement 706 to the horn 718. In some examples, the roller element 706may rotate about the axel 720 in a first direction 722. For example, thefirst direction 722 may be a clockwise direction. In some examples, thefirst direction 722 may be a clockwise direction with respect to theaxel 720. In some examples, the roller element 706 may rotate about theaxel 720 in a second direction 724. For example, the second direction724 may be a counter-clockwise direction. In some examples, the seconddirection 724 may be a counter-clockwise direction with respect to theaxel 720. In some examples, the roller element 706 may rotate about theaxel 720 in both the first direction 722 and the second direction 724.In some examples, the second direction 724 may be opposite the firstdirection 722.

In some examples, the roller element 706 may include a cylindrical body726, and an outer surface 728 of the cylindrical body 726 may beconfigured to physically contact one or more wood elements of theplurality of wood elements 710 while ultrasound energy is beingdelivered to the plurality of wood elements. For example, the rollerelement 706 may rotate about its axis in the first direction 722, or inthe second direction 724, and the outer surface 728 of the cylindricalbody 726 of the roller element 706 may physically contact one or morewood elements of the plurality of wood elements 710 as the cylindricalbody 726 of the roller element 706 rotates. In the depicted example ofFIG. 12A, it can be seen that the outer surface 728 will contact twowood elements (e.g., the two elements on the top of the 2×2 stack) ofthe plurality of wood elements 710 as the roller element 706 rollsacross the top of the plurality of wood elements 710.

FIG. 12B is a conceptual diagram of another example ultrasoundtransducer 730 that includes another example roller element 732. Theultrasound transducer 730 may be similar to ultrasound transducer 704described herein above with reference to FIG. 12A. The ultrasoundtransducer 730 may generate ultrasound energy, which may be guided fromthe ultrasound transducer 730 to the roller element 732 by an exampleultrasound horn 734, which may be coupled to the ultrasound transducer730 and may be configured to guide the ultrasound energy from thetransducer 730 to the roller element 732. The roller element 732, inthis example, includes a spherical body 736. That is, the roller element732 may generally have the shape of a sphere. An outer surface 738 ofthe spherical body 736 may physically contact one or more wood elements737 of a plurality of wood elements. Like the roller element 706 of FIG.12A, the roller element 732 may roll over wood elements, but in someimplementations the spherical body 736 of roller element 732 may roll inany number of directions 739 a, 739 b, 739 c, 739 d, 739 e, 739 f, 739g, 739 h, 739 i, 739 j and others, analogous to a ball used in earlycomputer mice rolling across a mouse pad, for example. For example, theroller element 732 may roll in any direction in a two-dimensional plane,according to some implementations. One or more example support members740 may provide mechanical support to the spherical body 736 of theroller element 732, according to some implementations. In some examples,the support members 740 may be rollers. In some examples, the supportmembers 740 may be pads, cushions, stops, or other appropriatecomponents for at least partially maintaining the roller element 732with respect to the horn 734. In some examples, there may be more orfewer support members 740 than are shown in FIG. 12B. In some examples,the ultrasound transducer 730, horn 734 and roller element 732 may besubstituted for the ultrasound transducer 704, horn 718 and rollerelement 706 of FIG. 12A.

In some examples, ultrasound energy may be delivered to the plurality ofwood elements via the roller elements 706 or 732. In variousimplementations, the ultrasound energy may have a frequency within arange of 10 kHz-20 MHz. In some examples, the ultrasound energy may havea frequency within a range of 15 kHz-1 MHz, or within a range of 20kHz-100 kHz. In some examples, the ultrasound energy may radiate fromthe outer surface 728 or 738 to the plurality of wood elements 710. Theultrasound energy may pass from the roller element 706 or 732 to theplurality of wood elements 710 by way of one or more of longitudinalultrasound waves, radiating ultrasound waves, or shear ultrasound waves,according to various implementations. In some examples, at least aportion of the outer surface 728 or 738 may remain in physical contactwith at least one wood element of the plurality of wood elements 710 asthe ultrasound energy is being delivered. In some examples, theultrasound energy may continue to be delivered when the outer surface728 or 738 is not in physical contact with any elements of the pluralityof wood elements 710, such as one or more of before, after, or bothbefore and after the outer surface 728 or 738 contacts the woodelements.

In some examples, the system that includes the ultrasound transducer 704or 730 and the roller element 706 or 732, respectively, may stimulatebonding of the wood elements by providing ultrasound energy to theplurality of wood elements 710. As described herein above with referenceto other systems for manufacturing composite wood products usingultrasound energy, the provided ultrasound energy may provide variousmechanical stimulations (e.g., vibratory stimulation at molecular andmacro levels) to the plurality of wood elements 710 and to the fillermaterial, may provide thermal stimulation to the plurality of woodelements 710 and to the filler material, may provide a diffusionalstimulation to the filler material, and friction generated between woodelements by the ultrasound energy delivery may further stimulate thebonding. Sonication pressure (e.g., pressure from the ultrasound waves)because of the provided ultrasound energy may also stimulate bonding ofthe plurality of wood elements. Advantageously, the ultrasoundtransducer 704 or 730 and roller element 706 or 732, respectively, maycontinuously stimulate the plurality of wood elements 710 and fillermaterial, which may beneficially aid in the bonding.

The roller element 706 or 732 may include any appropriate materials. Insome examples, the roller element 706 or 732 includes titanium. In someexamples, the roller element 706 or 732 includes aluminum. In someexamples, the roller element 706 or 732 may provide a compressive forceto the plurality of wood elements 710 as the outer surface 728 or 738rolls over the wood elements. In some examples, the roller element 706or 732 may not provide a compressive force to the plurality of woodelements as the outer surface 728 or 738 rolls over the wood elements.

In some implementations, the ultrasound transducer 704 or 730 may moveconcurrently with the roller element 706 or 732 as the roller element706 or 732 rolls over the plurality of wood elements 710. FIG. 12C is aconceptual diagram of an environment 742 for manufacturing compositewood products using ultrasound energy. An example ultrasound transducer743 includes an example horn 744 and example roller element 745, andthese may represent the transducers 704 or 730, horns 718 or 734, androller elements 706 or 732, respectively, of FIGS. 12A and 12B,according to some implementations. An example motion controller 746 maycontrol movement of the transducer 743 in some implementations. In someexamples, the motion controller 746 may control movement of thetransducer 743, and by extension the horn 744 and the roller element745. The motion controller 746 may include one or more motors (e.g.,servo motors, stepper motors, linear motors, direct drive motors, ACmotors, or DC motors, to list just a few examples), and may include amotion control module that may provide one or more signals to the one ormore motors, to control movement of the ultrasound transducer 743. Inthe example of FIG. 12C, the motion controller 746 is depicted separatefrom the ultrasound transducer 743, but in some implementations themotion controller 746 may be integral with the ultrasound transducer743.

Depending on the application, the motion controller 746 may control theultrasound transducer 743 to move in a variety of directions orpatterns. In some examples, the motion controller 746 may command theultrasound transducer 743 (and by extension the horn 744 and rollerelement 745, in some examples) to move linearly 748 (e.g., forward,backward, or each of forward and backward). In some examples, theultrasound transducer 743 may be configured to move in a single-axismotion system. In some examples, the motion controller 746 may commandthe ultrasound transducer 743 (and by extension the horn 744 and rollerelement 745, in some examples) to move in a two-dimensional pattern(e.g., move within a two-dimensional plane), such as a pattern to covera surface of one or more wood elements of a plurality of wood elements.In some examples, the motion controller 746 may command the ultrasoundtransducer 743 to move in a three-dimensional pattern (e.g., move withina three-dimensional space). FIG. 12C depicts a pattern 749 intended toshow that the ultrasound transducer in some examples (and by extensionthe horn 744 and roller element 745, in some examples) may move in anydirection in a three-dimensional space, where for simplicity and brevityarrows out of the page and into the page are not shown in the pattern749. In some examples, the ultrasound transducer 743 (and by extensionthe horn 744 and roller element 745, in some examples) may be configuredto move in a multi-axis motion system, such as a two-axis motion systemor a three-axis motion system.

In some examples, the motion controller 746 may include one or more of aprocessing component, a communications module, a memory, a power module,and one or more sensors. While these are not shown in FIG. 12C forsimplicity, in some examples the motion controller 746 may include oneof more of processing component 872, communications module 874, memory876, power module 878, and one or more sensors 880 of FIG. 15B, to bedescribed in more detail below with reference to FIG. 15B, and may usethese in providing the motion control functionality described above.

In some implementations, the ultrasound transducer 743 may be configuredto move along one or more tracks. In some implementations, theultrasound transducer 743 may be configured to move along one or morerails or sliders. In some examples, the ultrasound transducer 743 may beconfigured to move across a two-dimensional grid. In some examples, theultrasound transducer 743 may be configured to move across atwo-dimensional grid for a given height (or width, or depth) setting,and may be configured to move across the two-dimensional grid at avariety of height (or width, or depth) settings (e.g., to move within athree-dimensional space). Referring again to FIG. 12C, the ultrasoundtransducer 743 may be configured to move along or across a motion guide747. In some examples, the motion guide 747 may be one or more rails,sliders, or tracks. In some examples, the motion guide 747 may be atwo-dimensional grid. In some examples, the motion guide 747 may be amoveable two-dimensional grid, moveable in a third dimension differentfrom the two dimensions of the grid.

In some examples, the ultrasound transducer may remain generallystationary as the roller element rolls over the plurality of woodelements. In some examples, the horn may be configured to extend orretract as the roller element rolls over the plurality of wood elements,according to some implementations.

In some examples, both the horn and the roller element may be consideredto be part of the ultrasound transducer, and as such a portion of theultrasound transducer may be in physical contact with the wood elementsor the filler material while ultrasound energy is being delivered to theplurality of wood elements, according to some examples. In someexamples, the horn or the roller element may not be considered to bepart of the ultrasound transducer.

Whether the roller element includes a cylindrical body or a sphericalbody, the outer surface of the respective body may include variousfeatures, according to some examples. In some examples, the externalsurface of the cylindrical body 728 or spherical body 738 may besubstantially smooth, may include a plurality of protrusions, mayinclude a plurality of recessed features, or may include one or moreprotrusions and one or more recessed features.

FIG. 13A is a side view 750 of an example roller element 752, ultrasoundtransducer 754 and horn 756, each of which may respectively representthe roller element 706, ultrasound transducer 704 and horn 718 of theFIG. 12A example, or the roller element 732, ultrasound transducer 730and horn 734 of the FIG. 12B example. As can be seen in FIG. 13A, anouter surface 758 of the body of the roller element 752 is substantiallysmooth.

In some examples, the external surface of the body of the roller elementmay include a plurality of protrusions. FIG. 13B is a side view 760 ofanother example roller element 762, the ultrasound transducer 754, andhorn 756, each of which may respectively represent the roller element706, ultrasound transducer 704 and horn 718 of the FIG. 12A example, orthe roller element 732, ultrasound transducer 730 and horn 734 of theFIG. 12B example. As can be seen in FIG. 13B, an outer surface 764 ofthe body of the roller element 762 includes a plurality of protrusions766, where the protrusions 766 protrude from the outer surface 764.

In some examples, the external surface of the body of the roller elementmay include a plurality of recessed features, or features that arerecessed with respect to a surface of the roller element. FIG. 13C is aside view 780 of another example roller element 782, the ultrasoundtransducer 754, and horn 756, each of which may respectively representthe roller element 706, ultrasound transducer 704 and horn 718 of theFIG. 12A example, or the roller element 732, ultrasound transducer 730and horn 734 of the FIG. 12B example. As can be seen in FIG. 13C, anouter surface 784 of the body of the roller element 782 includes aplurality of recessed features 786, where the recessed features 786 arerecessed from the outer surface 784.

In various implementations, the protrusions 766 or recessed features 786may have various shapes. FIG. 14A is a front view 800 and FIG. 14B is atop view 802 of an example portion of an example roller element 804 thatincludes a plurality of example protrusions 806, 808, 810, 812, 814. Abody of the roller element 804 includes an outer surface 805 from whichthe protrusions 806, 808, 810, 812, 814 extend, or on which theprotrusions 806, 808, 810, 812, 814 are located. A first protrusion 806includes an outer surface 807 that is rounded. In some examples, thefirst protrusion 806 may generally have a “dome” shape. As can be seenin the top view 802 of FIG. 14B, a base of the first protrusion 806 hasthe shape of a circle, but any other appropriate shape (e.g., oval,square, rectangle, triangle, rhombus, diamond, or other appropriateshape) may alternatively be used for the base of the protrusion 806 witha rounded outer surface 807.

A second protrusion 808 includes an outer surface 809 that issubstantially flat. As can be seen in the top view 802 of FIG. 14B, abase of the second protrusion 808, as well as the outer surface 809 ofthe second protrusion 808 has the shape of a square, but any otherappropriate shape (e.g., oval, circle, rectangle, triangle, rhombus,diamond, or other appropriate shape) may alternatively be used for thebase or for the outer surface 809 of the protrusion 808 with asubstantially flat outer surface 809. In some examples, the base and theouter surface 809 of the second protrusion 808 may have differentshapes, including combinations of any of the aforementioned shapes.

A third protrusion 810 includes an outer surface that comprises a point811. In some examples, the point 811 may be an apex of the protrusion810. In some examples, the third protrusion 810 may generally have a“pyramid” shape. As can be seen in the top view 802 of FIG. 14B, a baseof the third protrusion 810 has the shape of a square, but any otherappropriate shape (e.g., oval, circle, rectangle, triangle, rhombus,diamond, or other appropriate shape) may alternatively be used for thebase of the protrusion 810 with an outer surface that comprises a point.

A fourth protrusion 812 includes an outer surface that comprises a ridge813. As can be seen in the top view 802 of FIG. 14B, a base of thefourth protrusion 812 has the shape of a rectangle, but any otherappropriate shape (e.g., oval, circle, square, triangle, rhombus,diamond, or other appropriate shape) may alternatively be used for thebase of the protrusion 812 with an outer surface that comprises a ridge.

A fifth protrusion 814 includes an outer surface having a shape of acylinder with a rounded top. The outer surface of the fifth protrusion814 includes a cylindrical-shaped side surface 816 and a rounded topsurface 815. As can be seen in the front view 800 of FIG. 14A, therounded surface 815 is raised and offset from the surface 805 of theroller element 804 by the cylindrical-shaped side surface 816. In someexamples, the fifth protrusion 814 may have a raised dome or cylindricalsilo shape. As can be seen in the top view 802 of FIG. 14B, a base ofthe fifth protrusion 814 has the shape of a circle, but any otherappropriate shape (e.g., oval, square, rectangle, triangle, rhombus,diamond, or other appropriate shape) may alternatively be used for thebase of the fifth protrusion 814.

FIG. 14C is a front view 820 and FIG. 14D is a top view 822 of anexample portion of an example roller element 824 that includes aplurality of example recessed features 826, 828, 830, 832, 834. A bodyof the roller element 824 includes an outer surface 825, from which therecessed features 826, 828, 830, 832, 834 are recessed or on which therecessed features 826, 828, 830, 832, 834 are located. A first recessedfeature 826 includes a surface 827 that is rounded. The first recessedfeature 826 may be a concave feature. The first recessed feature 826 mayhave the shape of a dimple. As can be seen in the top view 822 of FIG.14D, a base of the first recessed feature 826 has the shape of a circle,but any other appropriate shape (e.g., oval, square, rectangle,triangle, rhombus, diamond, or other appropriate shape) mayalternatively be used for the base of the recessed feature 826.

A second recessed feature 828 includes an outer surface 809 that issubstantially flat. As can be seen in the top view 822 of FIG. 14D, abase of the second recessed feature 828, as well as the outer surface829 of the second recessed feature 828 has the shape of a square, butany other appropriate shape (e.g., oval, circle, rectangle, triangle,rhombus, diamond, or other appropriate shape) may alternatively be usedfor the base or for the outer surface 829 of the recessed feature 828.In some examples, the base and the outer surface 829 of the secondrecessed feature 828 may have different shapes, including combinationsof any of the aforementioned shapes.

A third recessed feature 830 includes an outer surface that comprises apoint 831. In some examples, the point 831 may be a nadir of therecessed feature 830. In some examples, the point 831 may be the inverseapex of the recessed feature 830. As can be seen in the top view 822 ofFIG. 14d , a base of the third recessed feature 830 has the shape of asquare, but any other appropriate shape (e.g., oval, circle, rectangle,triangle, rhombus, diamond, or other appropriate shape) mayalternatively be used for the base of the recessed feature 830 with anouter surface that comprises a point.

A fourth recessed feature 832 includes an outer surface that comprises aridge 833, or a recessed ridge or inverted ridge. As can be seen in thetop view 822 of FIG. 14D, a base of the fourth recessed feature 832 hasthe shape of a rectangle, but any other appropriate shape (e.g., oval,circle, square, triangle, rhombus, diamond, or other appropriate shape)may alternatively be used for the base of the recessed feature 832 withan outer surface that comprises a ridge.

A fifth recessed feature 834 includes an outer surface 835 having ashape of a cylinder with a rounded bottom. The outer surface of thefifth recessed feature 834 includes a cylindrical-shaped side surface836 and a rounded bottom surface 835. As can be seen in the front view820 of FIG. 14C, the rounded surface 835 is recessed and offset from thesurface 825 of the roller element 824 by the cylindrical-shaped sidesurface 836. In some examples, the fifth recessed feature 834 may have asunken dome or inverted cylindrical silo shape. As can be seen in thetop view 822 of FIG. 14D, a base of the fifth recessed feature 834 hasthe shape of a circle, but any other appropriate shape (e.g., oval,square, rectangle, triangle, rhombus, diamond, or other appropriateshape) may alternatively be used for the base of the recessed feature834.

In some examples, the external surface of the cylindrical body mayinclude one or more protrusions and one or more recessed features. FIG.14E is a front view 840 of an example portion of an example rollerelement 842 that includes one or more example protrusions 806 and one ormore example recessed features 826. A body of the roller element 842includes an outer surface 844 from which the protrusions 806 extend andthe recessed features 826 are recessed, or on which the protrusions 806and recessed features 826 are located.

In some examples, the devices, systems and methods described herein maybe used to deliver varying amounts, or different amounts, of ultrasoundenergy to a plurality of wood elements, or may be used to deliverultrasound energy to one or more targeted areas or locations of theplurality of wood elements or within the plurality of wood elements, ormay be used to deliver combinations of the foregoing. In some examples,a first amount of ultrasound energy may be delivered to a plurality ofwood elements, and then a second amount of ultrasound energy may bedelivered to the plurality of wood elements. In some implementations,the first amount of ultrasound energy may have an intensity that ishigher than an intensity of the second amount of ultrasound energy. Insome implementations, the first amount of ultrasound energy may have anintensity that is lower than an intensity of the second amount ofultrasound energy. In some examples, a first amount of ultrasound energymay be delivered to a plurality of wood elements for a first duration oftime, and then a second amount of ultrasound energy may be delivered tothe plurality of wood elements for a second duration of time, which maybe different than the first duration of time (e.g., longer or shorterthan the first duration).

In some examples, a first amount of ultrasound energy may be deliveredto a first target location of, or within, a plurality of wood elements,and then a second amount of ultrasound energy may be delivered to asecond target location of, or within, the plurality of wood elements. Insome examples, the ultrasound transducer may remain stationarythroughout delivery of both the first amount of ultrasound energy to thefirst target location and delivery of the second amount of ultrasoundenergy to the second target location. In some examples, the ultrasoundtransducer, or one or more portions of the ultrasound transducer, maymove or be moved during delivery of the first amount of ultrasoundenergy to the first target location, during delivery of the secondamount of ultrasound energy to the second target location, or during thetime between delivery of the first amount and the second amount. Asnoted, ultrasound energy delivery can include various combinations ofdifferent amounts of ultrasound energy, for different durations, andtargeted to different locations of, or within, a plurality of woodelements.

FIG. 15A is a conceptual diagram 850 of an example control module 852and an example ultrasound transducer 854 delivering ultrasound energy toa plurality of example wood elements 856 for manufacturing a compositewood product using ultrasound energy. The example control module 852 mayprovide one or more control signals 857 to the example ultrasoundtransducer 854 to control one or more of an amount of ultrasound energy,an intensity of ultrasound energy, a duration for ultrasound energy, adepth for ultrasound energy delivery, and a location target forultrasound energy delivery, according to some examples. In general,control module 852 may be used with any of the example ultrasoundsystems described herein, and may be used to provide one or more of theaforementioned control signals 857 to the ultrasound transducer ortransducers in any of the example systems described herein. In someexamples, the control module 852 may provide one or more control signalsto more than one ultrasound transducer, although for brevity only asingle transducer 854 is depicted in FIG. 15A.

The example ultrasound transducer 854 has a generic shape, and mayrepresent any of the ultrasound transducer shapes or topologiesdiscussed herein. For example, transducer 854 may represent any of thetransducer and horn combinations discussed herein, and may represent anyof the transducer, horn and roller element combinations discussedherein.

FIG. 15B is a block diagram 870 of the example control module 852 ofFIG. 15A. The control module 852 includes a processing component 872, acommunications module 874, memory (including, for example, a data storein some examples) 876, and a power module 878. The processing component872 may include one or more microcontrollers, microprocessors, ordigital signal processors, in some examples, and may executeinstructions stored in memory 876 to perform tasks for the controlmodule 852. The communications module 874 may include a transmitter thatcan be used to transmit information, over wired connections directly insome examples, or in some examples via wired or wireless communicationsacross one or more networks (e.g., local area networks (LANs), wide areanetworks (WANs), the Internet, Wi-Fi networks, cellular networks,virtual private networks (VPNs), mobile data networks (e.g., 3G/4G/5Gnetworks, combinations of the foregoing, or others)).

In some examples, the communications module 874 includes a receiver thatcan be used to receive messages from other devices or systems. Thememory 876 may include one or more of types of volatile memory ornon-volatile memory including, in various examples, random-access memory(RAM), read-only memory (ROM), flash memory, storage devices (e.g.,solid-state hard drive, hard disc drive) and/or other forms of volatileor non-volatile memory.

The power module 878 may provide one or more power supply voltages topower components of the control module 852 or other devices orcomponents (e.g., transducer 854 in some examples). In some examples,the power module 878 can receive alternating current (AC) power, as froma wall outlet, and can convert the AC power into supply voltages usableby the control module 852 or other devices or components. In someexamples, the power module 878 includes a battery, which in someexamples may be rechargeable.

In some examples, control module 852 includes one or more sensors 880,such as, for example, one or more sensors that can detect when a woodelement or a plurality of wood elements is in a target position fordelivery of ultrasound energy. In some examples, the one or more sensors880 may sense ambient environment parameters, such as one or more oftemperature, humidity, barometric pressure, air quality, or otherenvironmental parameters. In some examples, the control module 852 mayreceive input from one or more external sensors, or from one or moreexternal devices in contact with one or more external sensors, and suchinput may provide the control module 852 with information relating toany of the foregoing sensor parameters. For example, the control module852 may receive an input from an external sensor that indicates that awood element or a plurality of wood elements is located in a targetposition for delivery of ultrasound energy.

A ultrasound delivery control module 882 can be used to manage orcontrol aspects of ultrasound energy delivery to the plurality of woodelements 856. For example, the ultrasound delivery control module 882may generate the one or more control signals 857 depicted in FIG. 15A.In various examples, the ultrasound delivery control module 882 may useinput from the one or more sensors 880, from the communications module874, and from memory 876, and may use the processing component 872 tomanage or control aspects of the ultrasound energy delivery. FIG. 15Bshows the ultrasound delivery control module 882 as a standalone modulefor simplicity, but in some implementations the module 882 may beincluded within the processing component 872. While the control module852 is depicted in a separate enclosure from the transducer 854 in FIG.15A, in some examples the control module 852, or one or more portions ofthe control module 852, may be located within the transducer 854.

With reference again to FIG. 15A, the control module 852 may direct, forexample via one or more control signals 857, the ultrasound transducer854 to deliver varying amounts of ultrasound energy to the plurality ofwood elements 856, which in this example includes wood elements 858 a,858 b, 858 c, and 858 d arranged vertically, in a similar manner to thewood elements of FIG. 4. In some examples, the control module 852 maydirect, for example via one or more control signals 857, the ultrasoundtransducer 854 to deliver ultrasound energy to various locations orportions of the plurality of wood elements 856.

The control module may direct that a first amount of ultrasound energy860 be delivered to a first location or portion of the plurality of woodelements, such as to wood elements 858 a, 858 b, and 858 c, for example.This may stimulate bonding of wood elements 858 a, 858 b, and 858 c, forexample. The control module may then direct that a second amount ofultrasound energy 862, such as a lower amount of ultrasound energy, bedelivered to a second location or portion of the plurality of woodelements, such as to wood element 858 d, for example, which maystimulate bonding of element 858 d to element 858 c. Each of elements858 a, 858 b, and 858 c may be one type of wood element, such as woodstrands, for example, and element 858 d may be another type of woodelement, such as a wood veneer, for example. The wood veneer 858 d maybe more delicate that the wood strands 858 a, 858 b, 858 c, for example,and may advantageously benefit from the lower amount of deliveredultrasound energy 860 in stimulating its bonding to element 858 c, forexample. In some examples, the control module 852 may include motioncontroller 746 of FIG. 12C, and may provide motion control functionalityto the ultrasound transducer 854.

In a general aspect, a system for manufacturing a composite wood productincludes an applicator configured to apply a filler material to aplurality of wood elements, and an ultrasound transducer configured todeliver ultrasound energy to the plurality of wood elements, where theultrasound energy has a frequency within a frequency range of 10 kHz-20MHz.

Implementations can include one or more of the following. The pluralityof wood elements may be bonded into a composite wood product. Theapplicator may include an adhesive applicator, and the filler materialmay include an adhesive. The filler material may not include anadhesive. The filler material may include a plastic. The filler materialmay include a metal. The plurality of wood elements may be arranged in aproximity to one another prior to the ultrasound transducer deliveringthe ultrasound energy to the plurality of wood elements. The applicatormay apply the filler material to the plurality of wood elementsconcurrently with the ultrasound transducer delivering the ultrasoundenergy to the plurality of wood elements. The ultrasound transducer maydeliver the ultrasound energy to the plurality of wood elements prior tothe applicator applying the filler material to the plurality of woodelements. The ultrasound transducer may deliver the ultrasound energy tothe plurality of wood elements after the applicator applies the fillermaterial to the plurality of wood elements. The system may also includea press configured to apply a compression force to the plurality of woodelements. The press may apply the compression force to the plurality ofwood elements prior to the ultrasound transducer delivering theultrasound energy to the plurality of wood elements. The press may applythe compression force to the plurality of wood elements concurrentlywith the ultrasound transducer delivering the ultrasound energy to theplurality of wood elements. The press may apply the compression force tothe plurality of wood elements after the ultrasound transducer deliversthe ultrasound energy to the plurality of wood elements. The ultrasoundenergy may have a frequency within a frequency range of 15 kHz-1 MHz.The ultrasound energy may have a frequency within a frequency range of20 kHz-100 kHz. The system may further include a defect inspectioncomponent, the ultrasound transducer may be further configured todeliver an additional amount of ultrasound energy to the composite woodproduct, and the defect inspection component may be configured toinspect the composite wood product for a defect. The defect inspectioncomponent may include a camera. The system may further include a defectinspection component and a second ultrasound transducer, the secondultrasound transducer may be configured to deliver ultrasound energy tothe composite wood product, and the defect inspection component may beconfigured to inspect the composite wood product for a defect. Thedefect inspection component may include a camera. The ultrasoundtransducer may be further configured to deliver ultrasound energy to theplurality of wood elements prior to the applicator applying the fillermaterial to the plurality of wood elements. The delivering theultrasound energy to the plurality of wood elements prior to theapplicator applying the filler material to the plurality of woodelements may clean the plurality of wood elements. The system mayfurther include a treatment applicator configured to apply a treatmentto the composite wood product, and the ultrasound transducer may befurther configured to deliver an additional amount of ultrasound energyto the composite wood product. The system may further include atreatment applicator and a second ultrasound transducer, the treatmentapplicator may be configured to apply a treatment to the composite woodproduct, and the second ultrasound transducer may be configured todeliver ultrasound energy to the composite wood product. The ultrasoundtransducer may be selected from the group of a Langevin transducer, aring transducer, a cymbal transducer, a dome transducer, a horntransducer, a pyramid transducer, a wedge transducer, and a sphericaltransducer. The ultrasound transducer may generate the ultrasound energyas a rectangular wave. The ultrasound transducer may generate theultrasound energy as a sinusoidal wave. The ultrasound transducer maygenerate the ultrasound energy as a wave selected from the group of atrapezoidal wave and a triangular wave. The ultrasound transducer maygenerate the ultrasound energy as a continuous waveform. The ultrasoundtransducer may generate the ultrasound energy as a pulsed waveform. Thesystem may further include a conveyor configured to transport theplurality of wood elements. The system may further include a funnelconfigured to guide the plurality of wood elements onto the conveyor.The system may further include a chamber configured to house theplurality of wood elements.

In a general aspect, a system for manufacturing a composite wood productincludes an applicator configured to apply a filler material to aplurality of wood elements and an ultrasound transducer configured togenerate ultrasound energy, where the ultrasound energy has a frequencywithin a frequency range of 10 kHz-20 MHz. The system also includes aroller element that includes a cylindrical body configured to rotateabout an axis, where the cylindrical body includes an outer surface. Thesystem further includes an ultrasound horn configured to guide theultrasound energy to the roller element, where the roller element isconfigured to deliver the ultrasound energy to the plurality of woodelements, and where the roller element is configured such that at leasta portion of the outer surface of the cylindrical body remains inphysical contact with at least one wood element of the plurality of woodelements as the ultrasound energy is being delivered.

Implementations can include one or more of the following. The outersurface of the cylindrical body may be substantially smooth. The outersurface of the cylindrical body may include a plurality of recessedfeatures. The outer surface of the cylindrical body may include aplurality of dimples. The outer surface of the cylindrical body mayinclude a plurality of protrusions. At least one protrusion of theplurality of protrusions may include an outer surface that is rounded.At least one protrusion of the plurality of protrusions may include anouter surface that is substantially flat. At least one protrusion of theplurality of protrusions may include an outer surface that includes apoint. At least one protrusion of the plurality of protrusions mayinclude an outer surface that includes a ridge. The plurality of woodelements may be bonded into a composite wood product. The applicator mayinclude an adhesive applicator, and the filler material may include anadhesive. The filler material may not include an adhesive. The fillermaterial may include a plastic. The filler material may include a metal.The plurality of wood elements may be arranged in a proximity to oneanother prior to the roller element delivering the ultrasound energy tothe plurality of wood elements. The applicator may apply the fillermaterial to the plurality of wood elements concurrently with the rollerelement delivering the ultrasound energy to the plurality of woodelements. The roller element may deliver the ultrasound energy to theplurality of wood elements prior to the applicator applying the fillermaterial to the plurality of wood elements. The roller element maydeliver the ultrasound energy to the plurality of wood elements afterthe applicator applies the filler material to the plurality of woodelements. The system may further include a press configured to apply acompression force to the plurality of wood elements. The press may applythe compression force to the plurality of wood elements prior to theroller element delivering the ultrasound energy to the plurality of woodelements. The press may apply the compression force to the plurality ofwood elements concurrently with the roller element delivering theultrasound energy to the plurality of wood elements. The press may applythe compression force to the plurality of wood elements after the rollerelement delivers the ultrasound energy to the plurality of woodelements. The ultrasound energy may have a frequency within a frequencyrange of 15 kHz-1 MHz. The ultrasound energy may have a frequency withina frequency range of 20 kHz-100 kHz. The system may further include adefect inspection component, the roller element may be furtherconfigured to deliver ultrasound energy to the composite wood product,and the defect inspection component may be configured to inspect thecomposite wood product for a defect. The defect inspection component mayinclude a camera. The roller element may be further configured todeliver ultrasound energy to the plurality of wood elements prior to theapplicator applying the filler material to the plurality of woodelements. The delivering the ultrasound energy to the plurality of woodelements prior to the applicator applying the filler material to theplurality of wood elements may clean the plurality of wood elements. Thesystem may further include a treatment applicator configured to apply atreatment to the composite wood product, and the roller element may befurther configured to deliver ultrasound energy to the composite woodproduct. The ultrasound transducer may generate the ultrasound energy asa rectangular wave. The ultrasound transducer may generate theultrasound energy as a sinusoidal wave. The ultrasound transducer maygenerate the ultrasound energy as a wave selected from the group of atrapezoidal wave and a triangular wave. The ultrasound transducer maygenerate the ultrasound energy as a continuous waveform. The ultrasoundtransducer may generate the ultrasound energy as a pulsed waveform. Thesystem may further include a conveyor configured to transport theplurality of wood elements. The system may further include a funnelconfigured to guide the plurality of wood elements onto the conveyor.The system may further include a chamber configured to house theplurality of wood elements.

In a general aspect, a system for manufacturing a composite wood productincludes an applicator configured to apply a filler material to aplurality of wood elements, and an ultrasound transducer configured togenerate ultrasound energy, where the ultrasound energy has a frequencywithin a frequency range of 10 kHz-20 MHz. The system also includes aroller element that includes a spherical body, where the spherical bodyincludes an outer surface. They system further includes an ultrasoundhorn configured to guide the ultrasound energy to the roller element,where the roller element is configured to deliver the ultrasound energyto the plurality of wood elements, and where the roller element isconfigured such that at least a portion of the outer surface of thespherical body remains in physical contact with at least one woodelement of the plurality of wood elements as the ultrasound energy isbeing delivered.

Implementations can include one or more of the following. The outersurface of the spherical body may be substantially smooth. The outersurface of the spherical body may include a plurality of recessedfeatures. The outer surface of the spherical body may include aplurality of dimples. The outer surface of the spherical body mayinclude a plurality of protrusions. At least one protrusion of theplurality of protrusions may include an outer surface that is rounded.At least one protrusion of the plurality of protrusions may include anouter surface that is substantially flat. At least one protrusion of theplurality of protrusions may include an outer surface that includes apoint. At least one protrusion of the plurality of protrusions mayinclude an outer surface that includes a ridge. The plurality of woodelements may be bonded into a composite wood product. The applicator mayinclude an adhesive applicator, and the filler material may include anadhesive. The filler material may not include an adhesive. The fillermaterial may include a plastic. The filler material may include a metal.The plurality of wood elements may be arranged in a proximity to oneanother prior to the roller element delivering the ultrasound energy tothe plurality of wood elements. The applicator may apply the fillermaterial to the plurality of wood elements concurrently with the rollerelement delivering the ultrasound energy to the plurality of woodelements. The roller element may deliver the ultrasound energy to theplurality of wood elements prior to the applicator applying the fillermaterial to the plurality of wood elements. The roller element maydeliver the ultrasound energy to the plurality of wood elements afterthe applicator applies the filler material to the plurality of woodelements. The system may further include a press configured to apply acompression force to the plurality of wood elements. The press may applythe compression force to the plurality of wood elements prior to theroller element delivering the ultrasound energy to the plurality of woodelements. The press may apply the compression force to the plurality ofwood elements concurrently with the roller element delivering theultrasound energy to the plurality of wood elements. The press may applythe compression force to the plurality of wood elements after the rollerelement delivers the ultrasound energy to the plurality of woodelements. The ultrasound energy may have a frequency within a frequencyrange of 15 kHz-1 MHz. The ultrasound energy may have a frequency withina frequency range of 20 kHz-100 kHz. The system may further include adefect inspection component, the roller element may be furtherconfigured to deliver ultrasound energy to the composite wood product,and the defect inspection component may be configured to inspect thecomposite wood product for a defect. The defect inspection component mayinclude a camera. The roller element may be further configured todeliver ultrasound energy to the plurality of wood elements prior to theapplicator applying the filler material to the plurality of woodelements. The delivering the ultrasound energy to the plurality of woodelements prior to the applicator applying the filler material to theplurality of wood elements may clean the plurality of wood elements. Thesystem may further include a treatment applicator configured to apply atreatment to the composite wood product, and the roller element may befurther configured to deliver ultrasound energy to the composite woodproduct. The ultrasound transducer may generate the ultrasound energy asa rectangular wave. The ultrasound transducer may generate theultrasound energy as a sinusoidal wave. The ultrasound transducer maygenerate the ultrasound energy as a wave selected from the group of atrapezoidal wave and a triangular wave. The ultrasound transducer maygenerate the ultrasound energy as a continuous waveform. The ultrasoundtransducer may generate the ultrasound energy as a pulsed waveform. Thesystem may further include a conveyor configured to transport theplurality of wood elements. The system may further include a funnelconfigured to guide the plurality of wood elements onto the conveyor.The system may further include a chamber configured to house theplurality of wood elements.

The above description provides examples of some implementations. Otherimplementations that are not explicitly described above are alsopossible, such as implementations based on modifications and/orvariations of the features described above. For example, the techniquesdescribed above may be implemented in different orders, with theinclusion of one or more additional steps, and/or with the exclusion ofone or more of the identified steps. Similarly, the devices, systems,and methods may include one or more additional features, may exclude oneor more of the identified features, and/or include the identifiedfeatures or steps combined in a different way than presented above.Features or steps that are described as singular may be implemented as aplurality of such features or steps. Likewise, features or steps thatare described as a plurality may be implemented as singular instances ofsuch features or steps. Additionally, the steps and techniques describedabove as being performed by some devices and/or systems mayalternatively, or additionally, be performed by other devices and/orsystems that are described above or other devices and/or systems thatare not explicitly described. The drawings are intended to beillustrative and may not precisely depict some implementations.Variations in sizing, placement, shapes, angles, curvatures, and/or thepositioning of features relative to each other are possible.Accordingly, other implementations are within the scope of the followingclaims.

1-20: (canceled)
 21. A method of manufacturing a composite wood product,comprising: applying a filler material to a plurality of wood elements;applying a compression force to the plurality of wood elements, thecompression force applied by a press, wherein the press includes a firstsurface that applies a first compression force to the plurality of woodelements and a second surface that applies a second compression force tothe plurality of wood elements; and bonding the plurality of woodelements into a composite wood product, the bonding comprisingdelivering ultrasound energy to the plurality of wood elements, whereinthe ultrasound energy has a frequency within a frequency range of 10kHz-20 MHz; wherein the ultrasound energy is delivered by a firstultrasound transducer that is integral with the press, and wherein thefirst ultrasound transducer is arranged to be flush with the firstsurface of the press.
 22. The method of claim 21, wherein the firstforce is in a first direction with respect to the plurality of woodelements and the second force is in a second direction with respect tothe plurality of wood elements, and wherein the second direction isdifferent than the first direction.
 23. The method of claim 22, whereinthe first direction is a downward direction and the second direction isa lateral direction.
 24. The method of claim 22, wherein the firstdirection is a lateral direction and the second direction is a downwarddirection.
 25. The method of claim 22, wherein the first direction is adownward direction and the second direction is one of a forwarddirection or a rearward direction.
 26. The method of claim 22, whereinthe first direction is one of a forward direction or a rearwarddirection, and the second direction is a downward direction.
 27. Themethod of claim 21, further comprising a second ultrasound transducerassociated with the second surface, wherein the first ultrasoundtransducer and the second ultrasound transducer each deliver portions ofthe ultrasound energy.
 28. The method of claim 27, wherein the secondtransducer is integral with the press.
 29. The method of claim 28,wherein the second ultrasound transducer is arranged to be flush withthe second surface.
 30. The method of claim 28, wherein the secondultrasound transducer is arranged to be recessed from the secondsurface.
 31. The method of claim 21, wherein the filler materialcomprises an adhesive.
 32. The method of claim 21, wherein the fillermaterial does not include an adhesive.
 33. The method of claim 21,wherein the filler material comprises a plastic.
 34. The method of claim21, wherein the filler material comprises a metal.
 35. The method ofclaim 21, wherein the plurality of wood elements are arranged, prior tothe bonding the plurality of wood elements, in a proximity to oneanother.
 36. The method of claim 21, wherein the ultrasound energy isdelivered to the plurality of wood elements after the applying thefiller material to the plurality of wood elements.
 37. The method ofclaim 21, wherein the applying the first and second compression forcesto the plurality of wood elements occurs prior to the delivering theultrasound energy to the plurality of wood elements.
 38. The method ofclaim 21, wherein the applying the first and second compression forcesto the plurality of wood elements occurs concurrently with thedelivering the ultrasound energy to the plurality of wood elements. 39.The method of claim 21, wherein the applying the first and secondcompression forces to the plurality of wood elements occurs after thedelivering the ultrasound energy to the plurality of wood elements. 40.The method of claim 21, wherein the frequency is within a frequencyrange of 15 kHz-1 MHz.
 41. The method of claim 40, wherein the frequencyis within a frequency range of 20 kHz-100 kHz.
 42. The method of claim21, further comprising inspecting the composite wood product for adefect, the inspecting comprising delivering ultrasound energy to thecomposite wood product.
 43. The method of claim 21, further comprising,prior to the applying the filler material, pretreating the plurality ofwood elements, the pretreating comprising delivering ultrasound energyto the plurality of wood elements.
 44. The method of claim 43, whereinthe pretreating comprising delivering ultrasound energy to the pluralityof wood elements cleans the plurality of wood elements.
 45. The methodof claim 21, further comprising, after the bonding into the compositewood product, applying a treatment to the composite wood product anddelivering ultrasound energy to the composite wood product.
 46. Themethod of claim 21, wherein the ultrasound energy comprises a firstamount of ultrasound energy and a second amount of ultrasound energy,wherein the first amount of ultrasound energy is delivered to a firstdepth of the plurality of wood elements, wherein the second amount ofultrasound energy is delivered to a second depth of the plurality ofwood elements, wherein the second depth is different from the firstdepth, and wherein the second amount of ultrasound energy is differentfrom the first amount of ultrasound energy.
 47. A method ofmanufacturing a composite wood product, comprising: applying a fillermaterial to a plurality of wood elements; applying a compression forceto the plurality of wood elements, the compression force applied by apress, wherein the press includes a first surface that applies a firstcompression force to the plurality of wood elements and a second surfacethat applies a second compression force to the plurality of woodelements; and bonding the plurality of wood elements into a compositewood product, the bonding comprising delivering ultrasound energy to theplurality of wood elements, wherein the ultrasound energy has afrequency within a frequency range of 10 kHz-20 MHz; wherein theultrasound energy is delivered by a first ultrasound transducer that isintegral with the press, and wherein the first ultrasound transducer isarranged to be recessed from the first surface of the press.
 48. Themethod of claim 47, wherein the first force is in a first direction withrespect to the plurality of wood elements and the second force is in asecond direction with respect to the plurality of wood elements, andwherein the second direction is different than the first direction. 49.The method of claim 48, wherein the first direction is a downwarddirection and the second direction is a lateral direction.
 50. Themethod of claim 48, wherein the first direction is a lateral directionand the second direction is a downward direction.
 51. The method ofclaim 48, wherein the first direction is a downward direction and thesecond direction is one of a forward direction or a rearward direction.52. The method of claim 48, wherein the first direction is one of aforward direction or a rearward direction, and the second direction is adownward direction.
 53. The method of claim 47, further comprising asecond ultrasound transducer associated with the second surface, whereinthe first ultrasound transducer and the second ultrasound transducereach deliver portions of the ultrasound energy.
 54. The method of claim53, wherein the second transducer is integral with the press.
 55. Themethod of claim 54, wherein the second ultrasound transducer is arrangedto be flush with the second surface.
 56. The method of claim 54, whereinthe second ultrasound transducer is arranged to be recessed from thesecond surface.
 57. The method of claim 47, wherein the filler materialcomprises an adhesive.
 58. The method of claim 47, wherein the fillermaterial does not include an adhesive.
 59. The method of claim 47,wherein the filler material comprises a plastic.
 60. The method of claim47, wherein the filler material comprises a metal.
 61. The method ofclaim 47, wherein the plurality of wood elements are arranged, prior tothe bonding the plurality of wood elements, in a proximity to oneanother.
 62. The method of claim 47, wherein the ultrasound energy isdelivered to the plurality of wood elements after the applying thefiller material to the plurality of wood elements.
 63. The method ofclaim 47, wherein the applying the first and second compression forcesto the plurality of wood elements occurs prior to the delivering theultrasound energy to the plurality of wood elements.
 64. The method ofclaim 47, wherein the applying the first and second compression forcesto the plurality of wood elements occurs concurrently with thedelivering the ultrasound energy to the plurality of wood elements. 65.The method of claim 47, wherein the applying the first and secondcompression forces to the plurality of wood elements occurs after thedelivering the ultrasound energy to the plurality of wood elements. 66.The method of claim 47, wherein the frequency is within a frequencyrange of 15 kHz-1 MHz.
 67. The method of claim 66, wherein the frequencyis within a frequency range of 20 kHz-100 kHz.
 68. The method of claim47, further comprising inspecting the composite wood product for adefect, the inspecting comprising delivering ultrasound energy to thecomposite wood product.
 69. The method of claim 47, further comprising,prior to the applying the filler material, pretreating the plurality ofwood elements, the pretreating comprising delivering ultrasound energyto the plurality of wood elements.
 70. The method of claim 69, whereinthe pretreating comprising delivering ultrasound energy to the pluralityof wood elements cleans the plurality of wood elements.
 71. The methodof claim 47, further comprising, after the bonding into the compositewood product, applying a treatment to the composite wood product anddelivering ultrasound energy to the composite wood product.
 72. Themethod of claim 47, wherein the ultrasound energy comprises a firstamount of ultrasound energy and a second amount of ultrasound energy,wherein the first amount of ultrasound energy is delivered to a firstdepth of the plurality of wood elements, wherein the second amount ofultrasound energy is delivered to a second depth of the plurality ofwood elements, wherein the second depth is different from the firstdepth, and wherein the second amount of ultrasound energy is differentfrom the first amount of ultrasound energy.